Edible coffee product prepared in the absence of atmospheric oxygen

ABSTRACT

Aspects of the present disclosure generally relate to systems and methods for processing biomaterials in the absence of atmospheric oxygen and products resulting from such processes. Such processing techniques may dramatically increase the shelf-life expectancies of roasted and milled biomaterial products when the roasted and milled biomaterial products are not exposed to oxygen during processing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/687,673, filed Nov. 18, 2019, now U.S. Pat. No. 10,834,937, entitled“SYSTEMS AND METHODS FOR PREPARING BIOMATERIALS IN THE ABSENCE OFATMOSPHERIC OXYGEN,” which claims the benefit of and priority under:

-   -   U.S. Patent Application No. 62/768,604, filed Nov. 16, 2018,        entitled “SYSTEMS AND METHODS FOR PREPARING BIOMATERIALS IN THE        ABSENCE OF ATMOSPHERIC OXYGEN”;    -   U.S. Patent Application No. 62/779,100, filed Dec. 13, 2018,        entitled “SYSTEMS AND METHODS FOR PREPARING BIOMATERIALS IN THE        ABSENCE OF ATMOSPHERIC OXYGEN”; and    -   U.S. Patent Application No. 62/881,690, filed Aug. 1, 2019,        entitled “SYSTEMS AND METHODS FOR PREPARING BIOMATERIALS IN THE        ABSENCE OF ATMOSPHERIC OXYGEN,”        all of which are incorporated herein by reference in their        entireties.

This application further incorporates by reference the following patentsand patent applications in their entireties:

-   -   U.S. Pat. No. 9,314,042, filed Nov. 26, 2012, entitled “METHOD        AND COMPOSITION USED FOR THE MANUFACTURE OF COFFEE LIQUOR”; and    -   U.S. patent application Ser. No. 16/309,674, filed Mar. 20,        2019, entitled “WHOLE COFFEE BASED PROCESSES AND PRODUCTS.”        Any incorporation by reference is not intended to give a        definitive or limiting meaning of a particular term. In the case        of a conflict of terms, this document governs.

BACKGROUND

Typically, biomaterials are processed under atmospheric conditions,where the oxygen component of the atmospheric air (around 21-23%) may befree to interact, as a component of the pre-heated air with thebiomaterials, as conductive heat to promote the roasting process. It isgenerally assumed that oxygen present in the air is either required toeliminate off-flavors or does not cause any harm to the thermolysisprocess. However, in some processes, the oxidation process isirreversible, self-replicating, and, self-accelerated, and suchoxidation can decrease flavor, aroma, and shelf-life of certainproducts.

In particular embodiments, when preparing roasted and groundbiomaterials such as coffee beans, the oxidation process may begin asearly as the very initial unit operations (i.e., the roasting andsubsequently the milling), and even at the green bean level, dependingon the elapsed time between harvesting and storage and/or storage androasting. One of ordinary skill in the art will recognize that theshelf-life of processed biomaterials, particularly coffee beans,generally do not exceed one year even under ideal storage conditions(e.g., frozen and vacuum sealed), and it typically ranges from a fewdays to a few weeks under usual conditions.

Moreover, conventional milling techniques may further exacerbate theoxidation process by increasing the exposed surface area of coffeebeans. In a complex oxidation process, primarily PUFA oils (such as thenatural coffee oil present) are subjected to a lipid peroxidation,through mechanisms of hydrogen abstraction, formation of conjugateddiene, followed by oxygen uptake, due to several factors, including: 1)the presence of oxygen and free-radicals; 2) the presence ofpro-oxidants; 3) the absence of antioxidants (in quantity or inconcentration); 4) the high temperature conditions of the process; 5)through the high heat supplied by the process, which provides highenergy of activation for reactions, and the potential to overcomeinter-atomic bond strength; 6) the presence of moisture (if over 2%),due to its hydrolytic effect in certain components; and 7) the presenceof catalysts, such as: iron, copper, magnesium, nickel, and others.

Potential consequences of traditional roasting and milling techniquesinclude the formation of peroxyl radicals that are self-replicatedthrough repeating sequence and cycles of oxidation reactions, thusaccelerating the initiation process of oxidation. Once oxidation isestablished, the sequence of events passes through propagation andtermination of the oxidative reactions, which may make the oxidationprocess irreversible, self-replicating, and self-accelerated, in theabsence of antioxidant agents.

In addition, milling can accelerate the oxidation process by increasingthe total surface (exposed) area of the biomaterial. For example, whenbiomaterials are milled to an average particle size of around 20microns, one gram of product is equivalent to about 190.3 sq. m (e.g.,about 2,050.0 sq. ft.) of total surface (exposed) area. The surfaceincrease related to the number of particles may be from around 1,920particles/g to over 100.3 million particles/g in the milled product,with respective increase of surface area.

Therefore, there is a long-felt but unresolved need for a system ormethod for roasting coffee beans, tea leaves, cannabis, and otherbiomaterials and/or derivative products, including their by-products, incomplete absence of atmospheric air (e.g., in the absence of oxygen).

BRIEF SUMMARY OF THE DISCLOSURE

Aspects of the present disclosure generally relate to systems andmethods for processing biomaterials in the absence of atmospheric oxygenand products resulting from such processes. Such processes may increasethe shelf-life expectancies and organoleptic characteristics of roastedand/or milled biomaterial products, including, but not limited to,coffee, cocoa, chocolate derivatives, edible nuts and related drinkableherbs products. In particular embodiments, biomaterials processedaccording to the systems and methods described herein generallyexhibited shelf-life greater than one year, either in opened or unopenedcontainers, or under various acceptable storing conditions.

In various embodiments, the systems and methods disclosed herein preventoxidation during the processing of biomaterials, via novel techniquesfor preparing, roasting, and milling biomaterials in an inert gasenvironment, in a closed or semi-closed loop, or other environmentsabsent of atmospheric oxygen. According to various aspects of thepresent disclosure, the systems and methods described herein may operatein absence of oxygen, including, but not limited to processing in avacuum, under normal atmospheric pressure, or pressurized conditions.

In some embodiments, the present disclosure aims to improve systems andmethods for preserving roasted biomaterials by converting biomaterialsinto the form of a liquid, paste and/or powder. Particularly, thepresent systems and methods aim to preserve coffee beans, cocoa beansand its chocolate derivatives, edible nuts (including: Brazil nuts,almonds, cashew nuts, hazelnuts, macadamias, walnuts, peanuts, and thelike), tea, matte and related drinkable herbs, biomaterial by-products,among others, in their roasted forms.

In some embodiments, the present systems and methods may producebiomaterial compositions in various forms, such as liquid, paste,powder, and other fat- and/or water-based soluble/dispersible forms. Inparticular embodiments, the approximate average size for final milledcoffee particles (or any other milled biomaterial discussed herein) mayrange from about 0.1-40.0 microns, less than about 40.0 microns, lessthan about 30.0 microns, or less than about 0.1 microns.

In particular embodiments, the systems and methods discussed hereinfacilitate the end-product wettability, water-solubility, and/or overalldispersibility (as well as other physical, chemical and/or rheologicalproperties). According to various aspects of the present disclosure,enhanced dispersion and stabilization of biomaterials may be achieved byagglomeration, microencapsulation, coating, and hardening of the coatingmaterial of the biomaterials with additives (e.g., dispersants,emulsifiers, thickeners, stabilizers, antioxidants, etc.), andcombinations thereof.

In particular embodiments, the system may include customized equipment,such as: 1) a special roaster designed to operate in absence of oxygen,which in at least one embodiment, may use an inert gas to act as a heattransfer medium; 2) a modified two-stage fluid bed cooler, equipped withquenching and “torrefacto” capabilities and for operating in absence ofoxygen; and 3) a cryogenic ball mill for ultra-milling of coffee beans,cocoa beans, edible nuts, teas and similar drinkable herbs, and theirderivatives (including by-products) to a particle size of less thanabout 40.0 microns, and as a method of wet milling for improvingdispersibility of insoluble particles of biomaterials.

In certain embodiments, the operational conditions of the presentsystems and methods use inert gases as a heat medium (e.g., in form ofsuperheated steam (SHS), or through any of the in-process heatedcommercial inert gases, such as nitrogen, helium, neon, argon, carbondioxide, or any other suitable inert gas). The atomic structure of aninert gas may provide a stable environment for the disclosed systems andmethods, such that inert gases include a full set of outer valenceelectrons (e.g., eight valence electrons) and are thus not prone toreactions (e.g., formation of covalent bonds) with other atoms and/ormolecules, such as oxygen, that do not have full sets of valenceelectrons. Particularly, oxygen atoms include six valence electrons andthus generally react with other atoms and/or molecules to fill its outerset of valence electrons (while also satisfying the other atoms ormolecules outer set of valence electrons). One having ordinary skill inthe art will recognize these types of reactions as covalent bonding andoxidation-reduction reactions. In certain embodiments, complementaryand/or additional/optional processing technologies may be included inthe disclosed systems and methods, such as the direct microencapsulationof the ultra-fine powder generated or, alternatively, the preliminaryagglomeration of ultra-fine particles and subsequent coating of theformed granules to uniquely allow the powdered version of finishedproduct to satisfy many of the above properties and features, while alsoensuring that the particles of the end-products may be completelyprotected against oxidation.

In a particular embodiment, packaging the resulting biomaterialpreparation in an inert gas environment, rather than an atmosphericenvironment, may further extend the preparation's shelf-life.

According to various aspects of the present disclosure, the systems andmethods discussed herein provide benefits such as: improve quality andsafety of consumption of food and beverages prepared with thesebiomaterials, provide shelf-life extension, enhanced convenience ofpreparation, improved yield extension, and extended storage andutilization without the use of chemical preservatives or refrigeration.

In various embodiments, the systems and methods disclosed herein allowfor the biomaterials to be processed while maintaining some, all, ormost of volatile and non-volatile components, and without damaging aromacomponents. For example, roasted coffee beans, cocoa beans, edible nuts,tea and similar drinkable herbs exhibit volatile and non-volatile aromacomponents. In the case of roasted coffee beans, around 14% of the beancontent is coffee essential oil, which could be processed, throughpre-extraction, storage, and preservation under cryogenic conditionsuntil it is ready to be eventually added back to the coffee mass-basedproducts, just before the process is completed. In particularembodiments, the system discussed herein includes supercritical fluidextraction (“SCFE”), a process for selective extraction of essentialoils from biomaterials (e.g., such as coffee oil from coffee beans).According to various aspects of the present disclosure, extracted fluidsmay include polyunsaturated fatty acids (“PUFAs”) which may be moreprone to oxidation, and thus removing PUFA may reduce risk ofbiomaterials becoming oxidized during roasting and milling processes andallows for greater shelf-life of the biomaterials. In variousembodiments, the PUFAs may be added back into the roasted and milledbiomaterials, if desired, after both the de-oiled biomaterial (e.g.,coffee stripped of coffee oil) and the essential oil (e.g., coffee oil)are protected from oxidation.

Aspects of the present disclosure aim to provide products thatefficiently retain the volatile and non-volatile chemicals and flavorcomponents of biomaterials during roasting and milling, resulting infoods and/or beverages with improved sensory characteristics, presentedin liquid, paste and/or in solid forms.

According to a first aspect, a process for producing a coffee fractionis disclosed including: cleaning and drying green coffee beans; roastingthe cleaned and dried green coffee beans to produce roasted coffee beansvia a roasting chamber, wherein the cleaned and dried green coffee beansare roasted in the absence of oxygen at a temperature of about 100-230degrees Celsius at a pressure of about 1-10 bar for about 2-60 minutes;cooling and transporting the roasted coffee beans via a two-stagevibratory fluid bed cooler in the absence of oxygen, wherein cooling theroasted coffee beans includes spraying the roasted coffee beans with asolution to quench thermolysis reactions; cryogenically dry milling theroasted coffee beans in the absence of oxygen to a particle size ofapproximately 75-100 microns at a temperature of about −190 to 10degrees Celsius; extracting fluids from the milled, roasted coffee beansin the absence of oxygen via a supercritical fluid extraction (SCFE)system to produce a coffee product, wherein the SCFE system includes:two or more extraction columns, each extraction column configured tointroduce supercritical liquid carbon dioxide to a permeation column;and each permeation column configured to introduce the supercriticalliquid carbon dioxide to the milled, roasted coffee beans therebycausing separation and extraction of the fluids from the milled roastedcoffee beans; wet milling the coffee product in the absence of oxygen ata temperature below about 10 degrees Celsius to produce a coffee powderincluding particles of less than about 40.0 microns; and mixing thecoffee powder with one or more oils and/or fats in the absence of oxygenat a temperature of about 10-80 degrees Celsius and at a pressure ofabout 1-5 bar to produce a coffee fraction including the coffee powderparticles microencapsulated in the one or more oils and/or fats.

According to a second aspect, the process of the first aspect or anyother aspects disclosed herein, wherein the cleaned and dried greencoffee beans are roasted in the presence of an inert gas. According to athird aspect, the process of the second aspect or any other aspectsdisclosed herein, wherein the roasting chamber is surrounded by aheating media for roasting the cleaned and dried green coffee beans.According to a fourth aspect, the process of the third aspect or anyother aspects disclosed herein, wherein the heating media includessuper-heated steam. According to a fifth aspect, the process of thethird aspect or any other aspects disclosed herein, wherein the heatingmedia includes an inert gas. According to a sixth aspect, the process ofthe third aspect or any other aspects disclosed herein, wherein theprocess further includes coating the coffee fraction via a coatingsprayer. According to a seventh aspect, the process of the sixth aspector any other aspects disclosed herein, wherein the coating sprayer isoperatively connected to a coating vibratory fluid bed. According to aneight aspect, the process of the seventh aspect or any other aspectsdisclosed herein, wherein the solution includes water. According to aninth aspect, the process of the eighth aspect or any other aspectsdisclosed herein, wherein the solution includes about 1-60% sugar.According to a tenth aspect, the process of the ninth aspect or anyother aspects disclosed herein, wherein the inert gas is nitrogen.

According to a eleventh aspect, a process for producing a coffeefraction is disclosed including: cleaning and drying green coffee beans;roasting the cleaned and dried green coffee beans to produce roastedcoffee beans via a roasting chamber, wherein the cleaned and dried greencoffee beans are roasted in the presence of an inert gas and in theabsence of oxygen at a temperature of about 100-230 degrees Celsius at apressure of about 1-10 bar for about 2-60 minutes; cooling andtransporting the roasted coffee beans via a two-stage vibratory fluidbed cooler in the absence of oxygen, wherein cooling the roasted coffeebeans includes spraying the roasted coffee beans with solution;cryogenically dry milling the roasted coffee beans in the absence ofoxygen to a particle size of approximately 75-100 microns at atemperature of about −190 to 10 degrees Celsius; extracting fluids fromthe milled, roasted coffee beans in the absence of oxygen via asupercritical fluid extraction (SCFE) system to produce a coffeeproduct, wherein the SCFE system includes: two or more extractioncolumns, each extraction column configured to introduce supercriticalliquid carbon dioxide to a permeation column; and each permeation columnconfigured to introduce the supercritical liquid carbon dioxide to themilled, roasted coffee beans thereby causing separation and extractionof the fluids from the milled roasted coffee beans; wet milling thecoffee product in the absence of oxygen at a temperature below about 10degrees Celsius to produce a coffee powder including particles of lessthan 40.0 microns; and mixing the coffee powder with one or more oilsand/or fats in the absence of oxygen at a temperature of about 10-80degrees Celsius and at a pressure of about 1-5 bar to produce a coffeefraction including the coffee powder microencapsulated in the one ormore oils and/or fats.

According to a twelfth aspect, the process of the eleventh aspect or anyother aspects disclosed herein, wherein the roasting chamber issurrounded by a heating media for roasting the cleaned and dried greencoffee beans. According to a thirteenth aspect, the process of thetwelfth aspect or any other aspects disclosed herein, wherein theheating media includes super-heated steam. According to a fourteenthaspect, the process of the thirteenth aspect or any other aspectsdisclosed herein, wherein the heating media includes an inert gas.According to a fifteenth aspect, the process of the thirteenth aspect orany other aspects disclosed herein, wherein the process further includescoating the coffee fraction via a coating sprayer. According to asixteenth aspect, the process of the fifteenth aspect or any otheraspects disclosed herein, wherein the coating sprayer is operativelyconnected to a coating vibratory fluid bed. According to a seventeenthaspect, the process of the sixteenth aspect or any other aspectsdisclosed herein, wherein the solution includes water. According to aneighteenth aspect, the process of the seventeenth aspect or any otheraspects disclosed herein, wherein the solution includes about 1-60%sugar. According to a nineteenth aspect, the process of the eighteenthaspect or any other aspects disclosed herein, wherein the processfurther includes agglomerating the coffee powder under the inert gasconditions and in the absence of oxygen. According to a twentiethaspect, the process of the nineteenth aspect or any other aspectsdisclosed herein, wherein the process further includes coating thecoffee powder under the inert gas conditions and in the absence ofoxygen.

These and other aspects, features, and benefits of the claimedinvention(s) will become apparent from the following detailed writtendescription of the preferred embodiments and aspects taken inconjunction with the following drawings, although variations andmodifications thereto may be effected without departing from the spiritand scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings illustrate one or more embodiments and/oraspects of the disclosure and, together with the written description,serve to explain the principles of the disclosure. Wherever possible,the same reference numbers are used throughout the drawings to refer tothe same or like elements of an embodiment, and wherein:

FIGS. 1A, 1B, and 1C illustrate a flowchart showing a biomaterial massmanufacturing process, according to one embodiment of the presentdisclosure.

FIGS. 2A, 2B, and 2C illustrate a flowchart showing a cleaning andsorting process, according to one embodiment of the present disclosure.

FIGS. 3A and 3B illustrate a flowchart showing a roasting andmanufacturing process, according to one embodiment of the presentdisclosure.

FIG. 4 illustrates an exemplary roasting system, according to oneembodiment of the present disclosure.

FIG. 5 illustrates an exemplary cooling system, according to oneembodiment of the present disclosure.

FIG. 6 illustrates an exemplary conche, distillation, and condensation(CDC) system, according to one embodiment of the present disclosure.

FIG. 7 illustrates an exemplary drying, agglomeration, and coating (DAC)system, according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings and specific language will be used todescribe the same. It will, nevertheless, be understood that nolimitation of the scope of the disclosure is thereby intended; anyalterations and further modifications of the described or illustratedembodiments, and any further applications of the principles of thedisclosure as illustrated therein are contemplated as would normallyoccur to one skilled in the art to which the disclosure relates. Alllimitations of scope should be determined in accordance with and asexpressed in the claims.

Whether a term is capitalized is not considered definitive or limitingof the meaning of a term. As used in this document, a capitalized termshall have the same meaning as an uncapitalized term, unless the contextof the usage specifically indicates that a more restrictive meaning forthe capitalized term is intended. However, the capitalization or lackthereof within the remainder of this document is not intended to benecessarily limiting unless the context clearly indicates that suchlimitation is intended.

As described herein, “heating” can be performed by one or a plurality ofheating elements such as, for example, electric heaters, radiativeheater, heat exchangers, and other mechanisms for generating andtransmitting heat to a substance.

As described herein, “cooling” can be performed by one or a plurality ofcooling elements such as, for example, refrigerated gas systems,cryogenic gas systems, heat exchangers, and other mechanisms for cooling(e.g., removing heat from) a substance.

As described herein, “pressurizing” can be performed by one or aplurality of pressurizing elements such as, for example, inert gascompressors, heat- and/or volume-based pressurization chambers, andother mechanisms for pressurizing a substance or structure containingthe substance.

Overview

Aspects of the present disclosure generally relate to systems andmethods for processing biomaterials in the absence of atmospheric oxygenand products resulting from such processes. Such processes may increasethe shelf-life expectancies and organoleptic characteristics of roastedand/or milled biomaterial products, including, but not limited to,coffee, cocoa, chocolate derivatives, edible nuts and related drinkableherbs products. In particular embodiments, biomaterials processedaccording to the systems and methods described herein generallyexhibited shelf-life greater than one year, either in opened or unopenedcontainers, or under various acceptable storing conditions.

In various embodiments, products contemplated herein include a wateractivity of less than 0.6 (e.g., products produced by the processesdiscussed herein). In some embodiments, final products (e.g., spreads,bars, chunks, thins, etc.) and masses of biomaterials may have aviscosity at least partially dependent upon particle size (e.g., ofpowdered coffee) and amount of biomaterial mass (e.g., coffee mass orcoffee fraction).

In various embodiments, to ensure effective protection and longershelf-life of the flavor of roasted coffee beans (or otherbiomaterials), preparation of the coffee in an edible format mayinclude, but is not limited to: 1) roasting and cooling using inert gasas heating or cooling medium; 2) “torrefacto” (in absence of oxygen); 3)cryogenic or refrigerated inert gas pre- and post-cooling (in absence ofoxygen); 4) metal detection (and removal) (under inert gas conditions);5) cryogenic or refrigerated inert gas dry pre-milling (in absence ofoxygen), to a particle size of about 75 to 500 microns or 300 to 400microns; 6) total or partial extraction of coffee oil by supercriticalfluid extraction (SCFE) and recovery of the oil under cryogenicconditions; 7) coating of de-oiled coffee micro-particles (e.g., in formof a mass) with specialty fats and/or oils (e.g., ghee, butter oil, palm(or fractions), palm kernel (or fractions), coconut oil (or fractions),and/or natural and/or deodorized cocoa butter); 8) special conching (inthe absence of oxygen), to develop a specific flavor profile for themass; 9) second (wet) cryogenic milling for fine-milling (in the absenceof oxygen), to reduce the particle size to less than 40 microns; 10)blending and/or homogenization of the coffee mass with specialty oilsand/or fats, using refined, bleached, and deodorized (RBD) and/or coldpressed oil products, such as fractionated coconut (e.g., medium chaintriglycerides, MCT), other drupe-based oils, as well as fruits-, nuts-,and/or cereals-based oil extractions; and 11) storage of the coffee massfor further processing.

An exemplary, non-limiting processes is as follows, according to oneembodiment (in the absence of oxygen). First, the system maypre-processes the biomaterials by dry cleaning and wet cleaning anddrying, as described herein. Second, the system may roast thebiomaterial for between about two (2) and sixty (60) minutes underconditions of an inert gas atmosphere inside a roasting chamber at atemperature between about 100-230 degrees Celsius and under vacuum or ata pressure between about 0.01-10 bars (with optional mechanicalvibration). Third, the system may process the biomaterials in atwo-stage fluid bed cooler (FBC) chamber configured to operate under aninert gas atmosphere conditions and where the hot roasted biomaterialmay be kept at a temperature between 65-75 degrees Celsius for a minimumof one (1) minute, and subsequently, the temperature of the roastedbiomaterial may be lowered to between about 15-30 degrees Celsius for aminimum of about five (5) minutes, while the biomaterials are exposed toa pressurized blow of cooled or cryogenic inert gas. Next, the FBC maydeliver cool water to quench the thermolysis of the roasted biomaterialsand/or deliver various sugar and/or sweetener solutions (from 10-60%w/w) via one or more sprayers (e.g., if a “torrefacto” process isdesired). Fifth, the system may mill the roasted and cooled biomaterial(after passing through metal detection) to a size between about 75 and500 microns at a temperature range between 10 to −190 degrees Celsius.Sixth, the system may mix the roasted and milled biomaterials withnatural cocoa butter or other suitable (edible) vegetable food oil orfat (from 0.5 to 10%) of the weight of the roasted and milledbiomaterial, by utilizing an industrial ribbon (or sigma type) mixer(adapted to operate under close- or semi-closed loop and using anysource of inert gas, in order to exclude completely the oxygen from theprocess, while incorporating the fat/oil onto the milled biomaterials).Seventh, the system may fully or partially extract fats/oils, throughsuper critical fluid-extraction (SCFE) via two or three stage extractioncolumns, where carbon dioxide in liquid form (i.e., under super criticalstate) is introduced into a permeation (filter) column at a temperatureof about 30-90 degrees Celsius.

In some embodiments, the liquid carbon dioxide may be introduced at apressure between about 150 to 450 bars to extract at least a portion ofoil and fat of the milled coffee beans (or other biomaterial). In someembodiments, the extraction operation may be interrupted when thebiomaterial reaches a residual of seven percent (7%) or less of fat/oil.In at least one embodiment, if the SCFE equipment is equipped withtwo-fluid collectors, it may then separate the natural essential oilfrom the added or natural fat present in the material. According toparticular embodiments, fat and oil (natural essential oil) might beoptionally sprayed back at the fluid bed stage during amicroencapsulation phase (of a powder), or to the agglomerated granules,during a coating and hardening phase. In further embodiments, naturalextracted cocoa butter, or other vegetable fat(s), may also be recoveredin pure form during the SCFE phase and may be re-utilized to prepare anew biomaterial product batch, during a mixing phase.

According to various embodiments, roasted, milled and carbon dioxidedefatted biomaterial may be ultra-milled through means of a cryogenic,vertical ball mill, after the material is initially covered with liquidNitrogen or liquid inert gas, following by a batch processing millingunder cryogenic conditions to a particle size of less than 40 micronsand, in one embodiment, with a narrow distribution range and an averageparticle size of between about 0.5-1.0 microns.

In one embodiment, milled, roasted biomaterials may be mixed with otherfood ingredients, and/or additives (under inert gas conditions), toyield liquid, paste or solid products or forms. In at least oneembodiment, the milled, roasted biomaterials are mixed with othersubstances via an industrial ribbon (or sigma type) mixer, adapted tooperate in a closed- or semi-closed loop in the absence of oxygen (e.g.,with inert gas).

In a particular embodiment, roasted biomaterials are conched, underspecific processing conditions, e.g., through a solid phase batchreactor (or conche). As will be understood, a conche process (in absenceof oxygen), may be utilized to develop secondary flavor-relatedreactions, such as those caused by, for example, Maillard reactions,Strecker degradation, and/or Schiff compound formation throughreactants, friction, shearing, and impact (which generate heat) andprocessing timing. In some embodiments, the process may includerecovering volatiles that escape from the biomaterials during the concheprocess, using a cryogenic-type aroma condenser. Exemplary machinery mayinclude several types of solid phase reactors, such as an extruder,and/or modern industrial conches, such as those employed in themanufacturing of chocolates, adapted for the following conditions: 1)operation in the absence of oxygen; 2) temperatures of about 10 to 80degrees Celsius; 3) pressure of about 1 to 20 bars; 4) a processingcycle or time of about 1 to 8 hours; and 5) a shaft rotation speed ofabout 25 to 100 rpm.

In some embodiments, the exemplary conche machinery may be operativelyconnected to an additional apparatus for injecting condensable strippinginert gases and using overheated steam at a minimum of about 1-5% of theinitial product mass used in combination with a cryogenic-type aromacondenser for the recovery of flavor volatiles under cryogenicconditions.

Exemplary Embodiments

Among other things, this disclosure is related to various embodiments ofprocessing biomaterials in the absence of oxygen. Further, thisdisclosure discusses various novel embodiments of machinery and systemsfor carrying out certain processing steps. As will be understood fromdiscussions herein, in some embodiments, biomaterials may be produced inthe absence of oxygen via machinery and systems that are closed-loop andinclude inert gas (or a vacuum if possible), where such machinery/systemis sealed from outside air. In at least one embodiment, biomaterials maybe produced in the absence of oxygen via machinery and systems that arecompletely enclosed in an oxygen-free environment (e.g.,machinery/systems are housed in an oxygen-free room, facility, floor ofa facility, container, or other enclosure). According to one embodiment,biomaterials are produced via machinery or systems that havetraditionally run with oxygen, but the machinery or systems are modifiedto be sealed from oxygen and any oxygen in the machinery or systems ispumped out or otherwise replaced with an inert gas.

Referring now to the figures, for the purposes of example andexplanation of the fundamental processes and components of the disclosedsystems and methods, reference is made to FIGS. 1A-1C, which illustratesa flowchart showing an exemplary manufacturing process 1000. As will beunderstood by one having ordinary skill in the art, the steps andprocesses shown in FIGS. 1A-1C (and those of all other flowcharts andsequence diagrams shown and described herein) may operate concurrentlyand continuously, are generally asynchronous and independent, and arenot necessarily performed in the order shown.

At step 10, the process 1000 includes receiving and storing commercialgrade green coffee beans. In various embodiments, green coffee beans,edible nuts, cocoa beans, or other biomaterials may be received undercommercial (exporting) phytosanitary conditions in bulk or bags. Incertain embodiments, the green coffee beans may be checked for weightand residual moisture for classification and sorting purposes.

In one or more embodiments, for tea and/or similar drinkable herbs, boththe dry and wet cleaning processes described herein may be adapted toaccommodate the physical conditions of the dried leaves and/or buds, andspecialized commercial equipment may be used to ensure complete cleaningand removal of solid impurities before the coffee (tea) mass, coffee(tea) fraction, and/or non-coffee (non-tea) fraction manufacturingprocesses. In at least one embodiment, the biomaterials can be preparedaccording to steps and processes described herein and using parametersselected based on characteristics of each biomaterial.

At step 20, the process 1000 includes performing dry post-cleaningprocesses on the green coffee beans. According to one embodiment, step20 of the process 1000 can include performing steps 2001-2070 of theprocess 2000 described herein. In at least one embodiment, the drypost-cleaning processes include removing elements from the green coffeebeans including, but not limited to: 1) coarse impurities; 2) dust; 3)sand; 4) chaff; 5) light (e.g., less-dense) coffee beans; 5) heavyimpurities; 6) stones and pebbles; 7) metal contaminants; 8) defectivebeans; and 9) other impurities. In various embodiments, drypost-cleaning processes generally includes manual, automatic, or acombination thereof of opening and emptying bags of green coffee beansand passing the green coffee beans through a sequence of unit operationsto eliminate impurities and clean the green coffee beans.

In one or more embodiments, the green coffee beans may be passed throughand treated by unit operations including, but not limited to: 1) atwo-sieve separator and classifier (also referred to as “Scalpelator” or“Dirt Wheel”) to eliminate coarse impurities; 2) an aspiration channel,to eliminate dust, sand, light beans and chaff; 3) a separator andde-stoner, to eliminate heavy impurities, stones and/or pebbles; 4) avibratory, multi-sieves sorter, to eliminate other impurities; 5) amagnetic separator, to separate metal contamination; and 6) a cluster,cutter, snipper and un-snipped bean remover, to separate defective beansfor partial recovery. In at least one embodiment, by passing the greencoffee beans through the above unit operations, the dry post-cleanedcoffee beans may demonstrate an average reduction in defects byten-fold.

At step 30, the process 1000 includes performing wet post-cleaningprocesses on the dry post-cleaned coffee beans. According to oneembodiment, step 30 of the process 1000 can include performing steps2072-2093 of the process 2000 described herein. In various embodiments,the wet post-cleaning processes may include, but are not limited to,passing the dry post-cleaned coffee beans through a second sequence ofunit operations. As will be understood by one of ordinary skill in theart, conventional methods for cleaning biomaterials such as coffee beansrely on dry cleaning (e.g., sifting, gas-blowing, etc.). According toone embodiment, the wet post-cleaning processes may improve cleanlinessof the dry post-cleaned coffee beans by removing impurities typicallyignored by dry cleaning methods, thereby allowing for the entirety ofthe dry post-cleaned coffee beans (e.g., the entirety of the coffeebeans) to be included in a coffee liquor product. In at least oneembodiment, the sequence of unit operations for wet post-cleaning mayinclude, but are not limited to: 1) a continuous counter-current (cool)water washer (to prevent excess water absorption by the beans), wherecoarse particles may be initially rejected by horizontal centrifugeduring primary cleaning, and where potable water used therein may besent to the primary water treatment and subsequently to the secondarywater treatment, before it is returned to the process; and 2) a wiremesh (vibratory) de-waterer, where further water recovery may beachieved, and continuously returned to the primary water treatment. Invarious embodiments, the wire mesh may be adaptable (e.g., changemesh/screen sizes) to accommodate various types of biomaterials (e.g.,in addition to the dry post-cleaned coffee beans). In at least oneembodiment, passing the dry post-cleaned coffee beans through the secondsequence of unit operations yields wet post-cleaned coffee beans.

At step 45, the process 1000 includes performing post-cleaning dryingprocesses on the wet post-cleaned coffee beans. According to oneembodiment, the wet post-cleaned coffee beans may demonstrate an initialaverage residual moisture of around 25 to 40%, and the post-cleaningdrying processes reduce the residual moisture percentage to about7-8.5%. In at least one embodiment, the post-cleaning drying processesmay include transferring the wet post-cleaned coffee beans to a beandrier that includes a two-stage vibratory stainless steel, mesh-typefluid bed chamber. In various embodiments, in a first stage, the wetpost-cleaned coffee beans may be received onto a vibratory bed within achamber, the vibratory bed configured to vibrate throughout the firststage. In one or more embodiments, to dry the wet post-cleaned coffeebeans, HEPA-type pre-filtered sanitary super-heated steam (SHS) may becontinuously injected upward into the first chamber at a constant,relatively low pressure and at a controlled volume and temperature.According to one embodiment, from the wet post-cooled coffee beans, thefirst stage can yield dried, heated coffee beans. In one or moreembodiments, the combination of the vibratory bed and SHS impingementcan cause a fluid bed effect, resulting in the dried, heated coffeebeans forming a fluid bed. In one or more embodiments, the fluid bedeffect (demonstrated by all fluid beds described herein) allows forincreased contact between the inert gas(es) and the coffee beans (orderivative thereof, or other biomaterials), thereby improving heattransfer (e.g., in heating and cooling related processes and stepsdescribed herein). In at least one embodiment, at the top portion of thechamber, humid air may be forcefully extracted and passed through acyclone configuration to recover any solid particulates from the dried,heated coffee beans.

In various embodiments, in a second stage, cool, HEPA-type pre-filteredinert gas may be continuously injected upwards into the fluid bed (e.g.,while the humid air exists through the top of the chamber through forcedextraction and subsequently passing through the cyclone configuration tocollect solid particulates). In at least one embodiment, the system mayoperate under closed-loop, where the humid inert gas passes through acondenser and absorbent filter, followed by a re-conditioning of theinert gas, in order to return to the loop. In one or more embodiments,while a small portion of the inert gas may exit the system, there mayalso be a secondary (automated) injection gas valve that may maintainthe constant level of circulating inert gas. According to oneembodiment, from the dried, heated coffee beans, the second stage canyield clean coffee beans. In various embodiments, the clean coffee beansmay demonstrate an average residual moisture of 7-8.5%, and may betransported and stored in metallic silos (e.g., for preservingcleanliness of the clean beans).

At step 50, the process 1000 includes performing classification andselection processes on the clean coffee beans. In various embodiments,the clean coffee beans can be sorted and classified based on factorsincluding, but not limited to, bean size, bean density, and/or beancolor. In at least one embodiment, an objective of the classificationand selection processes may be to ensure homogenous roasting levels(e.g., based on approximate similar size of beans of the clean coffeebeans). According to one embodiment, the classification and selectionprocesses may improve the overall quality of the final roasted productby providing size and shape-conformed coffee beans, thereby ensuringeven and consistent roasting (e.g., whereas roasting beans of differentsizes and shapes may produce inconsistent and irregular roasting). In atleast one embodiment, the classification and selection processes mayinclude passing the clean coffee beans through a third sequence of unitoperations that yield sorted quantities of clean coffee beans. In one ormore embodiments, the third sequence of unit operations includes, but isnot limited to: 1) a bean size sorter to classify the clean coffee beansby size into small, medium, and large bean categories; 2) a bean densitysorter (e.g., gravity separator) to eliminate light, perforated beansfrom the clean coffee beans for partial subsequent recovery; 3) anoptical color sorter to ensure homogeneity in color of the clean coffeebeans; 4) a peeler-polisher to peel and polish the clean coffee beans(e.g., to provide a better bean presentation of the clean coffee beans);and 5) if desired, a blender to blend the like-sized beans of the cleancoffee beans with like-sized beans of other clean and, in someembodiments, flavored coffees beans. In at least one embodiment, thethird sequence of unit operations sorts the clean coffee beans based onsize, color, and density into sorted quantities of clean coffee beans.In one example, the third sequence of unit operations yields small-,medium-, and large-sized quantities of clean coffee beans, each quantityalso being substantially similar in color. In the same example, thesmall-sized quantity of clean coffee beans may demonstrate an averagebean size measuring less than about 5.5 mm, the medium-sized quantity ofclean coffee beans may demonstrate an average bean size measuring lessthan about 6.5 mm (e.g., and greater than about 5.5 mm), and thelarge-sized quantity of clean coffee beans may demonstrate an averagebean size measuring less than about 8.0 mm (e.g., and greater than about6.5 mm).

At step 60, the process 1000 includes storing the sorted quantities ofclean coffee beans. In various embodiments, the sorted quantities ofclean coffee beans may be stored in distinct silos (e.g., distinctiondefined by size of coffee beans stored therein) and, thus, may beprocessed separately. For example, at step 60, a small-sized quantity ofclean coffee beans may be stored in a small bean silo, a medium-sizedquantity of clean coffee beans may be stored in a medium bean silo, anda large-sized quantity of clean coffee beans may be stored in a largebean silo. In at least one embodiment, clean coffee beans of dissimilarsizes may be recombined during or after one or more milling processesdescribed herein.

At step 70, the process 1000 includes blending the sorted quantities ofclean coffee beans of different sizes into a blended quantity of cleancoffee beans. For example, small-, medium-, and large-sized quantitiesof clean coffee beans can be blended into a blended quantity (e.g.,prior to further processing).

At step 80, the process 1000 includes roasting a size-sorted (or, insome embodiments, a size-combined/blended) quantity of clean coffeebeans to obtain roasted coffee beans. In one or more embodiments, toobtain the roasted coffee beans, the quantity of clean coffee beans canbe pressurized to about 1-10 bar and heated to about 100-230 degreesCelsius for a predetermined time period of about 2-60 minutes. Invarious embodiments, the roasting may be performed on whole coffee beans(e.g., prior to any milling of the coffee beans described herein).According to one embodiment, the roasting may be performed within aroasting system 4000 (FIG. 4 ). In one or more embodiments, the roastingmay be conducted under an inert gas atmosphere, in a closed orsemi-closed loop system, under pressure, vacuum, or normal pressure, andin the absence of oxygen.

In at least one embodiment, the inert gas may be nitrogen (N₂) oranother suitable inert gas. In various embodiments, heating media may beused to raise the temperature in an enclosed chamber that houses arotary cylinder and/or fluid bed containing the clean coffee beans. Inone or more embodiments, the coffee roasting can be performed in batchor continuous modes (e.g., depending on the volume of clean coffee beansto be processed).

In at least one embodiment, a roasting chamber may be initially filledwith an inert gas and maintained at a predetermined safe pressure, usinga relief valve to regulate the pressure. In various embodiments, aroasting pressure inside the roasting chamber may be kept between about1-10 bar, while a roasting temperature inside the rotary cylindersand/or or fluid bed chamber may be kept between about 100-230 degreesCelsius, in absence of oxygen. In one or more embodiments, the roastingmay extend over a predetermined roasting time period. In at least oneembodiment, the roasting time period may be about 2-60 minutes, and maydepend on a type of roasting profile desired. In various embodiments, aroasting level could be low, medium, or high. For example, a highroasting profile may include a longer roasting time period, higherroasting temperature, and higher roasting pressure, while a low roastingprofile may include a shorter roasting time period and lower roastingtemperature and pressure.

According to various aspects of the present disclosure, the systemsdiscussed herein can perform the roasting of biomaterials in the absenceof atmospheric oxygen. In various embodiments, roasting equipment may bemanufactured to function in both batch and continuous modes. In at leastone embodiment, the roasting may occur in various capacities, from 0.1kg up to 20,000 kg/batch or run. In various embodiments, the roastingequipment may be fabricated to operate sealed and in case of using anysuitable inert gas, may be built in closed- or semi-closed loopconfiguration (e.g., to minimize inert gas losses to the environment).

In at least one embodiment, roasting may occur under vacuum (0.1 bar),and/or atmospheric conditions (1 kg/sq. cm), and/or to medium-highpressure (up to 10 kg/sq. cm). In one or more embodiments, heating mediacan be used to heat and roast the clean coffee beans. In variousembodiments, the heating media can include, but is not limited to,super-heated steam (SHS) and/or any other suitable pre-heated inert gas,such as nitrogen, carbon dioxide, helium, argon, and the like. Accordingto one embodiment, the heating media can be in direct or indirectcontact with the clean coffee beans (or other biomaterials). In at leastone embodiment, the heating media can be heated by any type of heatingsource, including, but not limited to, electric sources, electromagneticsources, combustion-based sources. In one or more embodiments, theheating source can be located either internally or externally to theroasting equipment.

In various embodiments, upon roasting, the clean coffee beans can beconverted to roasted coffee beans. In one or more embodiments, coffeebean skins may be automatically or manually collected from the roastingequipment during or after the roasting of the clean coffee beans.According to one embodiment, the collected coffee bean skins can beconverted into pellets through one or more pelletizing techniques and/ormechanisms, and the pellets can be added to a burning boiler apparatus.Alternatively, coffee bean skins can be further processed for thepreparation of value-added products.

Precision, accuracy, and duration of coffee roasting can greatlyinfluence coffee flavor, and minor deviations in roasting level androasting duration can introduce undesirable off-flavors into the roastedcoffee. Previous approaches to coffee roasting utilize on-flame roastingequipment and roasting time periods of up to 9 minutes. The on-flameroasting equipment reduces the precision and accuracy of roastingprocesses, thereby leading to improper roasting levels and/or roastingperiods (e.g., resulting in roasting for less than 9 minutes) thatintroduce undesirable off-flavors into the roasted coffee. In at leastone embodiment, the roasting of process 1000 is performed usingoff-flame roasting equipment that allows for more controlled and uniformheating, thereby improving roasting precision and accuracy and providingfor improved flavor in the roasted coffee. In one or more embodiments,the roasting may be performed for a predetermined roasting periodgreater than about 9.0 minutes. In various embodiments, thepredetermined roasting period can be about 9.5-13.0 minutes, about9.0-9.5 minutes, about 9.5-10.0 minutes, about 10.0-10.5 minutes, about10.5-11.0 minutes, about 11.0-11.5 minutes, about 11.5-12.0 minutes,about 12.0-12.5 minutes, about 12.5-13.0 minutes, or about 13.0-13.5minutes, In at least one embodiment, the combination of off-flameroasting equipment and precisely and accurately controlled roastingperiods provide for roasted coffee (or other biomaterials) with improvedflavor (e.g., less off-flavors) compared to roasted coffee produced byprevious approaches.

At step 95, the process 1000 includes separating chaff from the roastedcoffee beans. In at least one embodiment, the roasted coffee beans canbe transported and/or fed into one or more chaff separators. In variousembodiments, the one or more chaff separators may continuously aspiratechaff from the roasted coffee beans. In one or more embodiments, thechaff aspiration can occur through a separation cyclone operating underinert gas conditions and in the absence of oxygen. According to oneembodiment, the one or more chaff separators can return clean inert gasback to the roasting equipment (e.g., to the roasting chamber), whilecontinuously separating the chaff from the roasted coffee beans.

At step 105, the process 1000 includes performing a “torrefacto” processon the roasted (and chaff-separated) coffee beans under inert gasconditions and in the absence of oxygen. In at least one embodiment, theroasted coffee beans can be sprayed with a 1-60% sugar solution heatedto about 1-90 degrees Celsius for a predetermined time period of about1-20 minutes. In one or more embodiments, the sugar solution forms acoating around each of the roasted coffee beans that improves resistanceto oxidation and/or provides a caramel-like flavor thereto.

In various embodiments, the torrefacto process may utilize a two-stagevibratory fluid bed cooler with a spraying mechanism to transport theroasted coffee beans. In one or more embodiments, a closed-loop inertgas, two-stage fluid bed cooler that can be used may be based on theStd. Model of the Food and Pharma Line, manufactured by Witte, 507 Rt.31 S. Washington, N.J. 07882.

In at least one embodiment, the torrefacto process can include a spraydevice. In at least one embodiment, step 105 may occur simultaneouslywith step 110 (e.g., and the pre-cooling process described herein). Invarious embodiments, the torrefacto process may include controllablyspraying a solution onto the roasted coffee beans, thereby substantiallyencapsulating the roasted coffee beans with the solution. In one or moreembodiments, the solution can be sprayed through one or more nozzles ofthe spraying mechanism. In various embodiments, the solution may includesugars from about 1-60% by weight of the solution, and the solution maybe sprayed at a temperature between about 1-90 degrees Celsius for atorrefacto time period of about 1-20 minutes. In one or moreembodiments, the solution imparts to the roasted coffee beans acaramel-like associated taste. In various embodiments, as a result ofthe encapsulation, the solution protects the roasted coffee beansagainst oxidation processes.

In at least one embodiment, the torrefacto process of step 105 may beperformed in a cooling system 5000 (FIG. 5 ). In various embodiments, ina first stage, the solution may be sprayed onto the roasted coffee beansthrough a spraying apparatus integrated within a two-stage closed- orsemi-closed loop fluid bed cooler operating under inert gas conditions.In at least one embodiment, the spraying apparatus may allow forincorporation of a variable amount of water, sugars and/or sweeteners tothe solution. In one or more embodiments, in the torrefacto process canquench the roasted coffee beans as they exit from the roasting process.According to one embodiment, in a second stage, the torrefacto processquenches thermolysis reactions occurring in the exiting roasted coffeebeans. In one example, the torrefacto process quenches the thermolysisreactions through latent heat of condensation that removes heat from theroasted coffee beans. In some embodiments, the spraying apparatus mayalso incorporate variable amounts of sweeteners at the surface of theroasted coffee beans, which may impart various tastes and specialflavoring to the roasted coffee beans under processing.

In embodiments where the “torrefacto” process in not performed, thespraying effect can be utilized to quench the thermolysis reaction ofthe roasted coffee beans. For example, the spraying apparatus can beconfigured to spray water (e.g., instead of the solution describedherein). In various embodiments, for quenching purposes, the system maydeliver finely spread cool and/or hot water through a spray nozzle(e.g., configured for single fluid or double fluid spray). According toone embodiment, the water may be at a temperature between about 1-90degrees Celsius and may be sprayed for a time period of about 1-20minutes.

At step 110, the process 1000 includes pre-cooling the roasted coffeebeans under inert gas conditions and in the absence of oxygen. Invarious embodiments, pre-cooling the roasted coffee beans may be carriedout through direct contact of the roasted coffee beans with refrigeratedinert gas (e.g., in total absence of oxygen). In one or moreembodiments, the roasted coffee beans may be cooled down in a firststage to a pre-cooling temperature between about 50-100 degrees Celsiusor about 65-70 degrees Celsius. In at least one embodiment, the roastedcoffee beans may be cooled down for at least 1 minute to interruptand/or quench the thermolysis processes of the roasted coffee beans.

At step 120, the process 1000 includes post-cooling the roasted coffeebeans under inert gas conditions and in the absence of oxygen. Invarious embodiments, post-cooling includes a second stage includingcontacting the roasted coffee beans with inert gas(es) at ambienttemperature to bring the temperature of the roasted coffee beans down toambient temperature (e.g., in total absence of oxygen). In one or moreembodiments, the roasted coffee beans may be post-cooled indefinitely(e.g., until the roasted coffee beans are further processes as describedherein).

In various embodiments, both the pre-cooling of step 110 and thepost-cooling of step 120 may be performed in a two-stage vibratory fluidbed cooler that simultaneously transports and cools the roasted coffeebeans. In at least one embodiment, a closed-loop inert gas customizedtwo-stage fluid bed cooler may be similar in part to the standard coolermodel of the Food and Pharma Line, manufactured by Witte, 507 Rt. 31 S.Washington, N.J. 07882—USA. In at least one embodiment, the pre-coolingmay occur in a first stage of the fluid bed cooler and the post-coolingmay occur in a second stage thereof. In one or more embodiments, thetorrefacto process of step 105 may occur prior to, following, orsimultaneously to the first stage of the fluid bed cooler (and/or thepre-cooling or processes described herein).

At step 130, the process 1000 includes degassing the roasted coffeebeans under vacuum and in the absence of oxygen. In various embodiments,the degassing may include, but is not limited to, keeping the roastedcoffee beans at ambient temperature and controlled pressure for apredetermined degassing period (e.g., about 1 day) to ensure completionof the degassing. In one or more embodiments, the present processingtechnology may include intermediary silos for storing the roasted coffeebeans while under degassing stage (e.g., to optimize the processingtime).

In various embodiments, all pre-cooling, post-cooling and de-gassing maybe performed under an inert gas environment by receiving a pressurizedblow of cooled inert gas together with a mechanical vibratory screen totransport the roasted coffee beans (e.g., in absence of oxygen).

According to various aspects of the present disclosure, the roastedcoffee beans may be kept at the pre-cooling temperature for a degassingtime period between about 5-30 minutes (or another appropriate amount oftime that allows for substantial degassing to occur). In at least oneembodiment, during the post-cooling stage of step 120, a temperature ofthe roasted coffee beans temperature may be brought down to apost-cooling temperature between about 20-30 degrees Celsius (e.g.,ambient temperature) in the second stage of the fluid bed. In variousembodiments, the roasted coffee beans may remain at the post-coolingtemperature indefinitely (e.g., the roasted coffee beans may be stableas the inert atmosphere is maintained). In at least one embodiment, thedegassing can include transporting the roasted coffee beans to one ormore holding tanks to undergo further degassing. In one or moreembodiments, the roasted coffee beans may remain in the one or moreholding tanks for a predetermined degassing period (e.g., up to about 2days), and may be held under compensated inert gas partial vacuum untilthe degassing is completed.

At step 140, the process 1000 includes detecting and separating metalfrom the roasted coffee beans. In various embodiments, the roastedcoffee beans may be submitted to a metal detection apparatus thatdetects and removes metal particles from the roasted coffee beans. In atleast one embodiment, the metal detection apparatus can utilize magneticelements (e.g., electromagnets, etc.) for detecting and selectivelyremoving the metal particles from the roasted coffee beans. In one ormore embodiments, detecting and removing contaminant metal from theroasted coffee beans may prevent damage to other system elements, suchas, for example, a mill utilized during milling processes and stepsdescribed herein.

At step 150, the process 1000 includes dry milling the roasted coffeebeans to a size of about 75-500 microns to create dry-milled coffeeparticles. In various embodiments, dry milling can be performed undercryogenic and inert gas conditions in the absence of oxygen. In variousembodiments, dry milling may be performed utilizing suitable equipmentincluding, but not limited to, commercial cryogenic or refrigeratedinert gas-type dry mills.

In one or more embodiments, the suitable equipment may be similar to thepin- or turbo-mill, and other suitable impact milling modelsmanufactured by companies such as Pallmann, Wolfstrasse 51, D-66482,Zweibrueken, Germany and Hosokawa Alpine, Peter Doerfler Strasse13-25,D-86199, Germany,—the latter marketed as model MP.

In various embodiments, the roasted coffee beans can be dry-milled downto a first predetermined particle size. In at least one embodiment, thefirst predetermined particle size may be between about 75-500 microns.In various embodiments, the first predetermined particle size may bebetween about 75-100 microns, about 100-150 microns, about 150-200microns, about 200-250 microns, about 250-300 microns, about 300-350microns, about 350-400 microns, about 400-450 microns, about 450-500microns, or about 500-550 microns. In one or more embodiments, narrowparticle size distribution may prevent blockages (e.g., filter plugging,etc.) in subsequent steps of the process 1000.

In various environments, the dry milling may be performed at atemperature range between 10 degrees Celsius and −190 degrees Celsius toensure suitable brittleness that improves efficiency of the dry milling.

At step 155, the process 1000 includes pre-mixing the dry-milled coffeeparticles with one or more specialty fats and/or oils in a quantityabout 0.5-15.0% by weight of the coffee particles while under inert gasconditions and in the absence of oxygen. In various embodiments, thepre-mixing can be performed in a closed- or semi-closed-loop ribbon- orsigma-type blender or mixer, or in another suitable blender or mixer. Inone or more embodiments, the ribbon- or sigma-type blender can includespraying mechanisms for spraying one or more specialty fats and/or oils(and other substances) onto the dry-milled coffee particles. As would beunderstood by one of ordinary skill in the art, multiple mixers and/orblenders can be used for the pre-mixing.

In one or more embodiments, one or more specialty fats and/or oils caninclude, but are not limited to: 1) fats and oils of vegetable origin,such as natural and/or deodorized cocoa butter; 2) medium chaintriglyceride (MCT) oil and/or other coconut fractionated and drupe-basedoils (fractionated or not); 3) fats from fruits, nuts, seeds; 4)cereal-based oils and/or fat extractions; 5) fats and/or oils of animalorigin, such as, for example, butter oil and/or ghee; and 6) othersuitable oils and/or fats. In at least one embodiment, the one or morespecialty fats and/or oils may be pre-mixed with the dry-milled coffeeparticles in a predetermined total content added from about 0.5-15%percent by weight of the dry-milled coffee particles. In at least oneembodiment, the total content added may be determined based on theamount and general stability of naturally occurring fats and/or oilswithin the dry-milled coffee particles (or a desired amount of fatsand/or oils in a product derived therefrom).

In various embodiments, parameters of the pre-mixing (e.g., thepredetermined total content, added content, pre-mixing speed, pre-mixingduration, etc.) may be based on the weight of the milled coffeeparticles. In one or more embodiments, the pre-mixing may incorporatethe specialty fats and/or oils with the dry-milled coffee particles,and, during the pre-mixing, fatty acids can crystallize, harden, andencapsulating the dry-milled coffee particles, thereby furtherpreventing oxidation thereof.

At step 160, the process includes performing a supercritical fluidextraction (SCFE) process on the dry-milled coffee particles (underinert gas conditions and in the absence of oxygen) to extract andrecover fats and oils therefrom. In various embodiments, the SCFEprocess can partially or totally extract fats and oils from thedry-milled coffee particles. In one or more embodiments, the SCFEprocess can utilize SCFE equipment to perform the partial and/or totalextraction of fats/oils. According to one embodiment, the SCFE equipmentmay be similar to a unit manufactured by Thyssenkrupp GmbH, BuschmuellenStrasse 20, D-58093, Hagen, Germany, under the UHDE brand, Germany ModelNo. 3x3100. In various embodiments, the SCFE equipment can includeextraction cells and/or loading and discharging systems for ensuring theabsence of oxygen during the SCFE process.

In at least one embodiment, the SCFE equipment may include two or moreextraction columns (e.g., load-charge cylinders) and one or morepermeation (filter) columns connected to the two or more extractioncolumns. In one or more embodiments, the dry-milled coffee particles areloaded into the two or more extraction columns and may be kept at apredetermined SCFE temperature between about 30-90 degrees Celsius.According to one embodiment, the SCFE temperature may be about 40degrees Celsius.

In various embodiments, the supercritical carbon dioxide may beintroduced into the one or more permeation columns at a predeterminedSCFE pressure between about 150-450 bar. According to one embodiment,the SCFE pressure may be about 250-350 psig. In at least one embodiment,the supercritical carbon dioxide permeates into the two or moreextraction columns and dissolves the dry-milled coffee particles. Invarious embodiments, the dissolved coffee particles are received by oneor more fraction collectors that are pressured and heated to suitabletemperatures and pressures that cause fats and oils to precipitate,thereby enabling their extraction from the dissolved coffee particles.Thus, in one or more embodiments, introduction of the supercritical,liquid carbon dioxide causes extraction of the oils and fats from thedry-milled coffee particles. In at least one embodiment, the SCFEprocess may conclude when the dry-milled coffee particles reach aresidual oil percentage at or below a predetermined SCFE threshold.According to one embodiment, the predetermined SCFE threshold may beabout 1-7%.

In various embodiments, coffee oil can be separated from the extractedfats and oils. In at least one embodiment, the coffee oil, extractedfats, and other extracted oils can be individually stored under inertgas conditions and in the absence of oxygen. In one or more embodiments,separation may be achieved by the SCFE equipment, for example, via oneor more separation mechanisms and one or more fluid collectors. In atleast one embodiment, the two or more fluid collectors separate thecoffee oil from the extracted fats and oils (including natural and addedfats and oils) so that the coffee oil and the extracted fats and oilscan be individually stored (e.g., under frozen conditions).

In at least one embodiment, the SCFE equipment can include two or moreseparation mechanisms that operate under internal, differential andcritical (controlled) pressures to separate oils and fats based ondiffering properties thereof. In one or more embodiments, the separationmay be completed due the internal, differential and critical pressuresthat allow for separation of the supercritical liquid carbon dioxidefrom the oil due to changes in the pressure inside of the two or moreextraction columns.

In various embodiments, the recovered fats and oils (e.g., coffeeessential oil and natural or added fats and oils), may be stored undercryogenic conditions and may then be then sprayed back, either at thefluid bed stage during microencapsulation/coating processes (e.g.,coating of the wet-milled coffee particles), or to the agglomeratedcoffee particles during the mixing, homogenization, blending, and/orplasticization processes. In one or more embodiments, previously addedfats and oils, or other natural vegetable fat(s) and oil(s) present mayalso be recovered in pure form during the SCFE and may be reutilized toprepare a new product batch.

According to various aspects of the present disclosure, the fats andoils of the roasted pre-milled biomaterials (e.g., natural essentialoil), which have been preserved under cryogenic conditions, may besprayed back to the product particles at the fluid bed drying stage,during the microencapsulation of the ultra-fine powder, or to theagglomerated granules during the coating phase. In at least oneembodiment, extracting the natural essential oils at the beginning ofthe process and furthermore adding the oils back, after roasting, allowsfor the taste and flavor provided by the natural essential oils to bepreserved, rather than destroyed or degrading during roasting orheating. In some embodiments, essential oils totaling about 14% of thebean (or other biomaterial) mass may be added back to the beans (orbiomaterial mass), when appropriate (e.g., during fluid bed coating). Insome embodiments, the amount may be less than 14% if less oil isextracted. In other embodiments, the percentage may be based on a typeof bean or biomaterial used. As an example, essential oils totalingabout 50% fat as cocoa butter may be added back to the beans if cocoabeans are used.

In some embodiments, extracted cocoa butter or other vegetable fat(s)and oil(s) may also be added. In various embodiments, these buttersand/or fats and/or oils may be recovered in approximately pure formsduring the SCFE phase, through appropriated variations in the systempressure. In certain embodiments, the separated fat may be reutilized inthe ribbon blender, whereas the oil may be protected from the processsteps until it can be added back at the end of the process, during thefluid bed coating.

At step 170, the process 1000 includes removing the SCFE-treated coffeeparticles from the SCFE equipment (e.g., the coffee particles locatedinside of load charge cylinders therein) and storing of the SCFE-treatedcoffee particles. In one or more embodiments, the removal of the coffeeparticles may be performed utilizing a scraping device configured tooperate under inert gas conditions and in the absence of oxygen. In atleast one embodiment, following removal, the SCFE-treated coffeeparticles may be deposited and stored in intermediary storage tanks.

At step 175-B, the process 1000 includes recovering the extracted coffeeoil. In one or more embodiments, the extracted coffee oil can berecovered from the SCFE equipment by one or more separation mechanisms.In at least one embodiment, the extracted coffee oil may be recoveredfrom the SCFE equipment into one or more collection filters connectedthereto. In various embodiments, the coffee oil extracted via the SCFEprocess may be highly purified.

At step 180-B, the process 1000 includes removing the recovered coffeeoil from the one or more collection filters (or other receptacle intowhich the coffee oil is recovered) and storing the coffee oil in one ormore coffee oil tanks (e.g., stainless steel vertical tanks) undercryogenic and inert gas conditions. In one or more embodiments, thecoffee oil may remain in the one or more coffee oil tanks until thecoffee oil may be utilized in other steps of the process 1000 (and otherprocesses discussed herein).

Turning to FIG. 1B, at step 210-B, the extracted coffee oil may bereceived and stored separate from the extracted fat based on the coffeeoil physical state being different from the extracted fat physical stateat ambient temperature. In one or more embodiments, while in storage,the coffee oil may remain in one or more oil tanks (e.g., stainlesssteel tanks) under inert gas atmosphere and kept at a storagetemperature while being slowly mixed via scraped-surface mixersconfigured in each oil tank. In at least one embodiment, additionalspecialty oils (e.g., additional coffee oil or other oils) may bereceived and stored into one or more additional oil tanks (under inertgas conditions and at the storage temperature), and the additionalspecialty oils may be slowly mixed via scraped-surface mixers configuredtherein.

At step 220-B, the process 1000 includes storing the specialty oil(e.g., coffee oil or other oils) under predetermined temperatureconditions. In at least one embodiment, storage can include pumping thecoffee oil and/or additional oils to one or more oil storage tanks andstoring the coffee oil and/or additional oils in the one or more oilstorage tanks under proper temperature conditions (e.g., heatedconditions, in some embodiments) until utilization during other steps ofthe process 1000. In various embodiments, each of the one or more oilstorage tanks includes a low-speed scraped-surface-type stirrer thatcontinuously agitates the stored coffee oil and/or additional oils. Inone or more embodiments, the one or more storage tanks may be maintainedunder inert gas conditions at an oil storage temperature dependent onthe oil stored to keep the stored coffee oil and/or additional oils in aphysical state suitable for utilization at other steps of the process1000. In one or more embodiments, the oil may be subsequently dosedusing positive displacement pump with automatic, pre-set flow control,and may be directed to further processing.

At step 210-A, the process 1000 includes storing the fats and/or oilsextracted via the SCFE process. In various embodiments, the extractedfats/oils may be stored in one or more fat tanks (e.g., stainless steeltanks) under inert gas conditions. In at least one embodiment, theextracted fats/oils may be pumped from the SCFE equipment into one ormore fat tanks. In one or more embodiments, additional fats/oils mayalso be stored at step 210-A. For example, additional fats/oils can bepumped into one or more additional fat tanks and stored therein underinert gas conditions.

At step 220-A, the process 1000 includes melting the extracted andstored fats by heating the fats above their melting point. In variousembodiments, the extracted fats may be melted with an indirect heatingmedia passed through serpentine melting mechanisms in contact with theextracted fats. In at least one embodiment, the heating media may bewater, and the heating media may be heated to a melting temperatureabove the fat melting point. In one or more embodiments, the extractedfats may be continuously held in a controlled, melted state to preventover-heating and eventual damage to chemical structures thereof. Invarious embodiments, the extracted fats may be held in the melted stateuntil utilization of the extracted fats during other steps of theprocess 1000.

In at least one embodiment, the additional fats stored in one or moreadditional fat tanks may also be melted (e.g., at step 220A) and held ina melted state until utilization during other steps of the process 1000.

At step 230-A, the process includes storing and, in some embodiments,continuously stirring the melted fats under heated conditions above thefat melting point. In at least one embodiment, the storing can includepumping the melted fats (including the melted extracted fats andadditional fats) to one or more melted fat storage tanks and storing themelted fats in one or more melted fat storage tanks until utilizationduring other steps of the process 1000. In various embodiments, each ofthe one or more melted fat storage tanks includes a low-speedscraped-surface-type stirrer that continuously agitates the stored fats.In one or more embodiments, the one or more melted fat storage tanks maybe maintained under inert gas conditions at a melted storage temperatureabove the fat melting point to keep the stored fats in a physical statesuitable for utilization at other steps of the process 1000. In one ormore embodiments, the stored fats may be dosed onto wet-milled coffeeparticles or other intermediary products described herein.

Returning to FIG. 1A, at step 180-A, the process 1000 includes wetmilling the SCFE-treated coffee particles under cryogenic and inert gasconditions and in the absence of oxygen to a predetermined particle sizeof about 0.1-40.0 microns or about 35.0-40.0 microns (or to less than40.0 microns). In various embodiments, the wet-milling can includesubmitting the SCFE-treated coffee particles to an ultra-milling stageof the ultra-mill equipment. In various embodiments, the wet milling ofthe SCFE-treated coffee particles may create a homogeneous paste (e.g.,also referred to as a coffee fraction or coffee liquor) of roasted andground coffee constituting a semi-finished product. In at least oneembodiment, the wet milling can convert the SCFE-treated coarse coffeeparticles into wet-milled fine coffee particles (e.g., that form thesemi-finished product).

In at least one embodiment, the particle size of wet-milled particlesmay be less than about 30 microns or less than about 40 microns. In oneor more embodiments, the particle size may be between about 0.1-40.0microns. According to one embodiment, the particle size may be betweenabout 0.1-2.0 microns, about 2.0-4.0 microns, about 4.0-8.0 microns,about 8.0-10.0 microns, about 10.0-12.0 microns, about 12.0-14.0microns, about 14.0-16.0 microns, about 16.0-18.0 microns, about18.0-20.0 microns, about 20.0-22.0 microns, about 22.0-24.0 microns,about 24.0-26.0 microns, about 26.0-28.0 microns, about 28.0-30.0microns, about 30.0-32.0 microns, about 32.0-34.0 microns, about34.0-36.0 microns, about 36.0-38.0 microns, about 38.0-40.0 microns,about 40.0-42.0 microns, about 42.0-44.0 microns, or about 44.0-46.0microns. In various embodiments, the particle size may be less thanabout 0.1 microns.

In at least one embodiment, the wet milling may be accomplished using acryogenic ultra-mill equipment. In various embodiments, the wet millingmay be carried out using a cryogenic ultra-mill equipment (for example,similar to equipment manufactured by Hosokawa Alpine, Germany, equipmentmodel MP) or other suitable wet mills, or through a vertical ball mill,operating under cryogenic conditions (for example, similar to equipmentmanufactured by the Union Process Machines, of Akron, Ohio—USA,manufactured under the Model S-30 Attritor series). In one or moreembodiments, during the wet milling, a cryogenic inert gas (such asliquid nitrogen) may be used to maintain a wet-mill processingtemperature down to about −190 degrees Celsius and cools theSCFE-treated coffee particles to a pre-wet-milling temperature of about−80 degrees Celsius prior to the wet milling to ensure a glassy(brittle) behavior in the SCFE-treated coffee particles. In at least oneembodiment (e.g., such as one involving highly roasted coffee), the wetmilling may occur under non-cryogenic conditions by using refrigeratedinert gas such that, during the wet milling process, the wet-millprocessing temperature and the pre-wet-milling temperature can bemaintained below 10 degrees Celsius to prevent the SCFE-treated coffeeparticles from becoming overheated and ensure glassy (brittle) behaviorin the SCFE-treated coffee particles. In at least one embodiment,SCFE-treated coffee roasted with a high roasting profile may bewet-milled under the non-cryogenic conditions.

In one or more embodiments, the wet-milled coffee particles producedfrom the wet milling may be handled using specialized HEPA filteringequipment to prevent dusting during the handling. In at least oneembodiment, the wet-milled coffee particles may be kept under an inertgas condition to prevent rapid aroma deterioration. In one or moreembodiments, the cryogenic conditions of the wet milling may allow thewet-milled coffee particles to exhibit electrical colloidal properties.Thus, in various embodiments, the wet-milled coffee particles may behaveas colloidal particles electrically charged at the surface. In at leastone embodiment, the electrical properties may improve efficiency ofprocesses carried out at other steps of the process 1000, such ascoating and hardening processes since the charged behavior improveslayer deposition around the wet-milled coffee particles. In variousembodiments, during the wet milling, a micronization of the coffeeparticles can occur. The coffee particles can be dispersed throughoutthe fat phase (or matrix) in a matrix-type encapsulation.

In one or more embodiments, the wet-milled coffee particles may besubjected to additional wet milling to ensure that particles thereofachieve the desired particle size. In at least one embodiment, theadditional wet milling can be carried out using a closed- or semi-closedloop jet mill, cryogenic or refrigerated inert gas mill, or any dry orwet milling-type equipment. In various embodiments, equipment used inthe additional wet milling may be similar to equipment manufactured byFluid Energy, 4300 Bethlehem Pike, Telford, Pa. 18969—USA, and marketedunder model Jet-o-Mizer. The equipment may be suitable to operate undercryogenic or refrigerated inert gas closed- or semi-closed loopconditions. According to one embodiment, the additional wet milling maybe carried out such that the SCFE-treated coffee particles undergohigh-speed inter-particle collisions and the wet-milled coffee particlesexhibit the colloidal properties.

Turning to FIG. 1B, at step 310, the process 1000 includes inducingflavor-forming reactions in the wet-milled coffee particles by extrudingand/or conching the wet-milled coffee particles (or other pre-refinednon-coffee particles). In at least one embodiment, during a processingcycle of about 1-6 hours or about 10 minutes, the wet-milled coffeeparticles can be pressurized to about 1-5 bar and heated to about 10-80degrees Celsius while being agitated with an agitation mechanismoperating at about 25-150 rpm. In various embodiments, thepressurization, heating, and agitation conches and induces the flavor-and color-forming reactions in the wet-milled coffee or pre-refinednon-coffee particles.

According to one embodiment, an extrusion and/or conching processinduces and facilitates the completion of one or more flavor- andcolor-generating reactions in the wet-milled coffee or pre-refinednon-coffee particles. In at least one embodiment, the extrusion and/orconching process improves the homogenization of ingredients addedthereto (e.g., in other steps of the process 1000). In one or moreembodiments, the flavor- and color-generating reactions include, but arenot limited to, Maillard reaction or non-enzymatic browning, includingStrecker degradations and/or Schiff base. As described herein, Maillardreaction generally refers to a chemical reaction between amino acids andreducing sugars that generates and provides flavor and color compoundsto the wet-milled coffee or pre-refined non-coffee particles by anon-enzymatic browning effect. As described herein, Streckerdegradations generally refers to chemical reactions that converts, byway of an intermediate, amino acids (such as a-amino acids) into analdehyde (including the a-amino acid as a side chain) or 2-aminocarbonylcompound or other chemical substance that act as intermediates in thegeneration of aromas during Maillard reactions. As described herein, aSchiff base (or imine) generally refers to an intermediary productduring Maillard reaction, which is involved in the initiation andpropagation of the Maillard reaction.

In one or more embodiments, the conching process can be performed in anextruder, such as a double-screw extruder. In at least one embodiment,the extruder can be configured to operate under variable pressuresincluding low- or high-vacuum pressure (e.g., pressure of about −720torr), medium pressure (e.g., for example pressure of about 1-2 bar orabout 14.6 psig), and high pressure (e.g., pressure of about to about3,500 psig).

In one or more embodiments, at the beginning of the conching process,the wet-milled coffee or pre-refined non-coffee particles maydemonstrate a residual moisture content below about 12.5%. In at leastone embodiment, the wet-milled coffee particles may be dried orotherwise treated to reduce the residual moisture content thereof belowabout 12.5%. In various embodiments, the wet-milled coffee orpre-refined non-coffee particles may be loaded into the extruder and theextruder may be depressurized to about 14.6 psig (under inert gasconditions and in the absence of oxygen). In one or more embodiments,the depressurization causes the wet-milled coffee or pre-refinednon-coffee particles to expand. In at least one embodiment, followingexpansion, the wet-milled coffee or pre-refined non-coffee particles canbe loaded into the conching system.

In various embodiments, two or more screws of the extruder cancontinuously agitate the expanded, wet-milled coffee or pre-refinednon-coffee particles. According to one embodiment, the two or morescrews may include, but are not limited to, threaded screws, rootedscrews, crested crews, pitched screws, chamfered screws, and/orspecialized dies for providing a particular form or consistency in aconched, wet-milled coffee or pre-refined non-coffee particles producedfrom the conching process. In at least one embodiment, the extruder canbe configured (e.g., via jackets, etc.) to operate under cryogenicconditions and/or at temperature between about 10-70 degrees Celsius. Inone or more embodiments, the two or more screws may agitate (e.g.,conche) the expanded, wet-milled coffee or pre-refined non-coffeeparticles for a processing time up to about 1 to 6 hours and at aprocessing temperature of about 10-70 degrees Celsius, thereby inducingand facilitating the completion of the Maillard reaction. In variousembodiments, the agitation performed by the two or more screws conchesthe expanded, wet-milled coffee or pre-refined non-coffee particles,thereby causing emission of volatiles and other substances that arerecovered, stored, and utilized in other steps of the process 1000 asdescribed herein.

In some embodiments, the conching process can include processing thewet-milled coffee or pre-refined non-coffee particles through conchingequipment including, but not limited to, a conche system (for example,similar to a conche system supplied by Buehler AG, Uzwil, Switzerland)configured for conching process conditions described herein. In one ormore embodiments, the conching process can include only extruder-basedprocesses or only conche system-based processes, or may include bothprocesses, the conche system-based processes being performed on outputof the extruder-based processes.

In at least one embodiment, the conche system can be configured tooperate under inert gas conditions and in the absence of oxygen. In oneor more embodiments, the conche system may subject wet-milled coffeeparticles to conditions including, but not limited to: 1) distinctprocessing temperature profiles from about 10-80 degrees Celsius orabout 10-70 degrees Celsius; 2) operating pressures from about 1-5 baror about 1-2 bar; 3) processing cycles from about 1-6 hours, or about 10minutes; 4) agitating shaft rotations at speeds of about 25-150 rpm orabout 50 rpm with reverse shaft rotation capabilities; 5) agitatingpaddles configured to rotate and counter rotate throughout the conchingprocess as described herein; 6) processing times of about 2-7 hours; and7) injection of condensable stripping inert gases (i.e., overheatedinert steam at a minimum of 1-5% by weight of the wet-milled coffeeparticles) to enable a cryogenic-type aroma recovery of flavor volatilesemitted from the wet-milled coffee particles. In one or moreembodiments, the conching equipment may include a conche, distillation,and condensation system described in 6000 (FIG. 6 ).

In one or more embodiments, the conche system processes and conches thewet-milled coffee or pre-refined non-coffee particles in one or moresolid phase reactors and/or industrial conche including an agitatingmechanism (e.g., a controllable rotating screw). In various embodiments,the conche system conches the wet-milled coffee or pre-refinednon-coffee particles according to the parameters and conditionsdescribed herein, thereby inducing and facilitating the completion ofthe Maillard reaction and causing the emission of volatiles, aromas, andother substances.

In at least one embodiment, the conche system or extruder is connectedto a recovery system including one or more fractionating distillationcolumns. In various embodiments, each fractionating distillation columnincludes one or more stages. In one or more embodiments, such a stagemay include a steam stripping-off system that collects and removesvolatiles and other substances associated with off-flavors, therebyeliminating the off-flavors from the conched, wet-milled or pre-refinedparticles. In at least one embodiment, the base of one or moredistillation columns may be connected to an outlet of the conche systemor extruder, thereby allowing the passage of volatiles and othersubstances to the recovery system. In one or more embodiments, therecovery system includes a number of trays (e.g., 3-5 trays). In atleast one embodiment, each tray can be connected to a tray outlet and/ora separation outlet designed for fractional condensation of volatiles,aromas, and other substances (under inert gas, vacuum and/orrefrigerated/cryogenic conditions). In certain embodiments, the trayoutlets and/or separation outlets may converge to the trays for aromafractionation and recovery. In one or more embodiments, the recoverysystem may be similar to an EPIC Processing Systems machine, amanufacturer located at 4141 Meramec Bottom Rd, St. Louis, Mo., USA.

In some embodiments, the conche system or extruder may include amechanism for facilitating extraction and recovery of volatiles, aromas,and other substances (e.g., in condensable gas form) that are emitted bythe conched, wet-milled coffee or pre-refined non-coffee particles. Inone or more embodiments, the mechanism injects inert gases from theconche system or extruder into one or more fractionating distillationcolumns of the recovery system. In at least one embodiment, the injectedinert gases contain the volatiles, aromas, and other substances emittedby the conched, wet-milled coffee or pre-refined non-coffee particles.In one or more embodiments, super-heated steam (SHS) of a predeterminedquantity can be injected through one or more fractionating distillationcolumns, thereby stripping, in condensable gas form, the volatiles,aromas, and other substances from the injected inert gases. In one ormore embodiments, the predetermined quantity of SHS may be about 1-5% byweight of the wet-milled coffee or pre-refined non-coffee particles. Inone or more embodiments, the SHS (including the volatiles, aromas, andother substances) can pass from one or more fractionating distillationcolumns into one or more cryogenic-type condensers for condensing andrecovering the volatiles, aromas, and other substances.

In at least one embodiment, the recovery system coupled to the conchesystem or extruder may be utilized as a stand-alone fractionateddistillation column (or set thereof) for the recovery of volatiles,aromas, and/or other substances from the conched, wet-milled coffee orpre-refined non-coffee particles. In various embodiments, the recoverysystem can include equipment utilized in chemical, perfumery andcosmetic processing. In one embodiment, the equipment can be similar toequipment available by Bufflovak LLC, of Buffalo, N.Y., USA. In variousembodiments, the equipment may be utilized for the cryogenic recovery ofvolatiles and product add-back of several volatiles that escape throughthe gas stripping during drying processes of the conching process.

In one or more embodiments, flashing includes partially evaporating asaturated liquid stream (e.g., condensed from recovered inert gases) toreduce a pressure thereof and cause formation of partial (e.g., flashed)vapor that contains volatile compounds that may be in a higherconcentration, in the vapor, than in the liquid stream. In at least oneembodiment, the flashing can be performed by passing the liquid streamthrough a throttling device (e.g., a throttling valve) that reduces thepressure (e.g., a vapor pressure) of the stream.

At step 275, the process 1000 includes flashing volatiles, aromas, andother substances present in the inert gases recovered from the conchingprocesses described herein. In one or more embodiments, the flashing maybe carried out for the recovery of the volatiles, aromas, and othersubstances that are emitted during conching processes and/or extrusionprocesses. In various embodiments, the conche system and/or extruderincludes flashing equipment connected to a vent line of the conchesystem and/or extruder. In one or more embodiments, the equipment mayinclude, but is not limited to, flashing mechanisms and one or morefractioning distillation columns for the recovery of aromatics from theflashed volatiles, aromas, and other substances under cryogenicconditions. In at least one embodiment, the equipment may be equipmentutilized in the chemical, perfumery and cosmetic processing industry,and similar to commercially available machines through companies such asBufflovak LLC, of Buffalo, N.Y.

At step 285, the process 1000 includes fractionating and/or distillingvolatiles, aromas, and other substances from the wet-milled coffee orpre-refined non-coffee particles emitted during the conching processdescribed herein. In various embodiments, volatiles distillation and/orfractionation may include equipment which may be connected to a ventline of the special conche. In one or more embodiments, the equipmentmay include, but is not limited to, a fractionated/distillation columnfor the recovery of aromatics under cryogenic conditions. In at leastone embodiment, the equipment may be equipment utilized in the chemical,perfumery and cosmetic processing industry, and similar to commerciallyavailable machines through companies such as Bufflovak LLC, of Buffalo,N.Y.

At step 295, the process 1000 includes storing recovered aromas,distillates, and other substances individually and under cryogenicconditions. In various embodiments, the recovered distillates may bestored in cryogenic tanks for further utilization during add-backprocesses described herein. In one or more embodiments, the distillatesmay be utilized for the cryogenic recovery of volatiles and productadd-back of several volatiles that may escape through the gas strippingduring the one or more drying stages of the conching process describedherein.

Returning to FIG. 1 , at step 190-A, the process 1000 includesencapsulating the wet-milled coffee with additional oils and fats and/orother ingredients to create microencapsulated coffee particles. Invarious embodiments, as used and described herein, “encapsulation” and“microencapsulation” typically refer to encapsulating one particle ormultiple particles in one or more substances (e.g., solutions, fats,oils, other food ingredients, etc.), and “coating” can refer to coatingmultiple, agglomerated particles or single particles. In one or moreembodiments, encapsulation, microencapsulation and coating (andderivatives thereof) can be used interchangeably herein.

In one or more embodiments, the other ingredients and/or additives mayinclude, but are not limited to, sugar, dairy ingredients and othersubstances to diversify potential end-products and applications for theencapsulated coffee particles. In at least one embodiment, the fats andoils can include, but are not limited to: 1) natural or deodorized cocoabutter or other suitable oils or fats; 2) medium chain triglyceride(MCT) coconut-fractionated or other drupe-based fats and/or oils; 3)fruit-derived oils and/or fat extractions; 3) nut-derived oils and/orfat extractions; 4) seeds-based oil and/or fat extractions; 5)cereal-based oil and/or fat extractions; 6) animal-derived oils and/orfats, such as butter oil and/or ghee; and 7) melted and stored fatsand/or oils, such as the fats and/or oils stored and melted at step230-A. In at least one embodiment, the oils and/or fats may be inrefined, bleached, and deodorized (RBD) form, and may have been cold- orhot-pressed.

In various embodiments, the wet-milled coffee particles can be mixed orblended with a predetermined quantity of the oils and fats and/or otheringredients. In at least one embodiment, the predetermined quantity maybe about 0.5-15% by weight of the wet-milled coffee particles. In one ormore embodiments, the mixing or blending can be performed using mixingequipment including a ribbon- or sigma-type blender or mixer (or anothersuitable type of blender or mixer) configured to operate under a closedor semi-closed loop and use a vacuum modified atmosphere of inertgas(es). In at least one embodiment, the mixing equipment can beconfigured such that atmospheric oxygen (or any oxygen) does not contactthe wet-milled coffee particles during the mixing or blending. Accordingto one embodiment, the mixing and/or blending can be performed at speedsof about 20-150 revolutions per minute (rpm), about 100 rpm, or about10-100 rpm and in capacities up to about 5 kg, up to about 50 kg, or upto about 15,000 kg per processing run (though greater capacities arealso contemplated). In one or more embodiments, the mixing equipment canperform the mixing or blending via rotating double-helices thatcontrollably rotate within the mixing equipment (e.g., at the speedsbetween 20-150 rpm or 10-100 rpm). In at least one embodiment, whenmelted and stored fats are utilized, the melted and stored fats can bepumped from one or more fats storage tanks into the blender or mixer (orby internal spraying mechanisms thereof) using positive displacementpumps with automatic, pre-set flow controls.

In various embodiments, the fats and oils and/or other ingredients canbe added (e.g., mixed or blended in a predetermined quantity) at step155 as described herein. In at least one embodiment, a first portion ofthe fats and oils can be extracted with coffee oil from the dry-milledcoffee particles at step 160 and a second portion of the fats and oilscan remain in the dry-milled coffee particles (e.g., and may or may notbe removed during wet-milling processes described herein).

In at least one embodiment, the wet-milled coffee particles can bereceived in a hermetically sealed interior chamber. In one or moreembodiments, the mixing equipment can include an internal sprayingmechanism including one or more ultra-fine, double-fluid, atomizer-typenozzles arranged in the interior chamber. In various embodiments, theinternal spraying mechanisms can be connected to reservoirs of the oilsand/or fats and/or other ingredients. In at least one embodiment, theone or more ultra-fine, two-fluid nozzles can automatically andcontrollably spray, mist or flow the fats and/or oils and/or the otheringredients into the interior of the mixing equipment and onto thewet-milled coffee particles.

In at least one embodiment, the spray system can controllably spray thefats and/or oils and/or the other ingredients into the interior chamber,thereby encapsulated the wet-milled coffee particles to createencapsulated coffee particles. In one or more embodiments, the spraysystem can spray the fats and/or oils and/or the other ingredients in aquantity of about 0.5 to 15%, or up to about 200%, by weight of thewet-milled coffee particles. In at least one embodiment, the spraysystem may spray the fats and/or oils and/or the other ingredients asfinely dispersed droplets (e.g., with average drop sizes of up to 100microns).

In at least one embodiment, the spray system can perform the spraying inone or more running cycles of a predetermined duration (e.g., 1-100minutes). In one or more embodiments, a predetermined number of one ormore running cycles may be performed as a processing run. In one or moreembodiments, before, during, and after a processing run, the walls ofthe internal chamber of the mixing equipment may heat the wet-milled (orcoated) coffee particles to a heating temperature equal to a meltingpoint of the fats and/or oils (e.g., about 90 degrees Celsius for somefats and/or oils) and/or cool the wet-milled (or coated) coffeeparticles to a cooling temperature less than a melting point of the fatsand/or oils (or about 10 degrees Celsius). In at least one embodiment,the walls may include or interface with heating and cooling elements tocause the heating and cooling. In various embodiments, during a singleprocessing run, the wet-milled (or coated) coffee particles can be heldat the heating temperature for a predetermined heating time period andheld at the cooling temperature for a predetermined cooling time period.

At step 195, the process 1000 includes agglomerating and/ormicroencapsulating the coated coffee particles (or wet-milled coffeeparticles) with food ingredients and/or additives to create a coffeefraction. In one or more embodiments, the agglomerating and/ormicroencapsulating protects coffee fraction from oxidation and enhancesthe dispersibility and stability during the preparation of the coffeefraction (e.g., in liquid dispersions). According to one embodiment, thecoated coffee particles may only be agglomerated. According to oneembodiment, the coated coffee particles may only be microencapsulated.

In at least one embodiment, the agglomerating and the microencapsulatingcan occur within the same equipment. In various embodiments, theequipment can include, but is not limited to, a closed- or semi-closedloop fluid bed drier (FBD). In at least one embodiment, the equipmentmay include a drying, agglomeration, and coating system 7000 (FIG. 7 ).In one or more embodiments, the FBD can be configured to controllablydry and cool the coated coffee particles.

In at least one embodiment, the agglomeration can include, but is notlimited to: 1) pre-wetting the coated coffee particles with controlleddispersions of water or aqueous solutions at (e.g., that may be at acold or hot temperature); 2) loading the coated coffee particles intothe FBD; 3) agglomerating the coated coffee particles into anagglomerated coffee mass by iteratively wetting and drying the coatedcoffee particles; and 4) drying the agglomerated coffee mass. In atleast one embodiment, the agglomerated coffee mass can be dried byleaving the agglomerated coffee mass within the FBD for a predetermineddrying period (e.g., thereby allowing the agglomerated coffee mass todry). In one or more embodiments, drying the agglomerated coffee masscan include performing residual dehydration by providing dried and lowrelative humidity conditions inside the FBD. In at least one embodiment,the residual dehydration can prevent the coffee mass from adhering tothe FBD interior (and, in some embodiments, to itself). In one or moreembodiments, during the agglomerating and the microencapsulating, theFBD can be configured to operate under heated (or refrigerated) inertgas conditions in the absence of oxygen. In various embodiments, theagglomerating can occur on a batch or continuous basis.

In some embodiments, the microencapsulating can include directlyspraying the agglomerated coffee mass (or coated coffee particles) withsuitable food ingredients and/or additives that (further)microencapsulate coffee particles of the agglomerated coffee mass. Inone or more embodiments, the suitable food ingredients and/or additivesfor microencapsulation may include, but are not limited to, coconut oiland its fractions, palm kernel oil and its fractions, and othermaterials. In at least one embodiment, the suitable food ingredientsand/or additives may be included in their refined, bleached, anddeodorized forms, or may be included in one or more other forms. In oneor more embodiments, the microencapsulating can confer improveddispersibility and stability to the agglomerated coffee mass (or coatedcoffee particles).

In some embodiments, the process may be carried out in the FBD (e.g.,the FBD being configured to operate under refrigerated inert gas anddehumidified environment conditions). In various embodiments, the FBDcan be configured to perform the microencapsulating in batches orcontinuously. In at least one embodiment, the FBD can includefreeze-drying elements that can freeze-dry the agglomerated coffee mass(or derivative thereof).

In various embodiments, the spraying mechanism includes one or moreultra-fine, double-fluid, atomizer-type nozzles arranged in the interiorof the FBD. In at least one embodiment, the one or more ultra-fine,two-fluid nozzles can automatically and controllably spray, mist or flowthe food ingredients and/or additives onto the agglomerated coffee mass.In one or more embodiments, the spraying mechanism can spray the foodingredients and/or additives in a quantity of about 0.5 to 15%, or up toabout 200%, by weight of the agglomerated coffee mass. In at least oneembodiment, the spray system may spray the ingredients and/or additivesas finely dispersible droplets (e.g., with average drop sizes of up to100 microns). In at least one embodiment, the ingredients and/oradditives can be pulverized into a microencapsulating solution and/ordispersion (e.g., through the spraying system via the one or moretwo-fluid nozzles).

In at least one embodiment, the spraying mechanism controllably andcontinuously (or on a batch basis) sprays the microencapsulatingsolution onto the agglomerated coffee mass (or coated coffee particles)to apply a film coating thereto that microencapsulates coffee particlestherein. In at least one embodiment, the microencapsulating solution canbe sprayed in a quantity measuring about 0.5-15% by weight of theagglomerated coffee mass. In various embodiments, the quantity may beselected to accommodate a desired level of coating protection to thecoffee fraction created from the agglomerated coffee mass. In one ormore embodiments, the quantity may be selected to provide, in a productderived from the coffee fraction, desirable physical and/or chemicalproperties. In one example, the desirable physical and/or chemicalproperties include a predetermined solubility or dispersion propertywhen the product is dispersed into liquids or foods of particulartemperatures (e.g., hot or cold).

In at least one embodiment, additional oils and/or fats can be pumped tothe spraying system and sprayed onto the agglomerated coffee mass duringmicroencapsulating. In one or more embodiments, the additional oilsand/or fats can include, but are not limited to: 1) stored fats andcoffee oils extracted during the roasting processes described herein;and 2) other stored specialty fats and/or oils described herein. Invarious embodiments, the additional oils and/or fats can be sprayed in aquantity of about 1-30% by weight of the agglomerated coffee mass.

In at least one embodiment, following the agglomerating andmicroencapsulating, coffee particles of the coffee fraction may eachinclude a coating of a predetermined mass. In one or more embodiments,the predetermined mass may be up to 5% by weight of the coffee particle.

In at least one embodiment, following the agglomerating andmicroencapsulating, the coffee fraction can be cooled. In one or moreembodiments, the coffee fraction can be controllably cooled using atwo-stage vibratory fluid bed cooler (FBC). According to one embodiment,the FBC can be included in the FBD described herein. In variousembodiments, the FBD may be configured to operate in a closed- orsemi-closed loop under inert gas conditions and in the absence ofoxygen. In at least one embodiment, the FBC may be similar to a standardmodel of the Food and Pharma Line, manufactured by Witte, 507 Rt. 31 S.Washington, N.J. —07882—USA.

In various embodiments, the coffee fraction can be cooled to a firstcooled temperature between about 50-100 degrees Celsius or about 65-75degrees Celsius for a first cooling period of about 1 minute. In one ormore embodiments, following the first cooling period, the coffeefraction can be cooled to a second cooling temperature of about 18-25degrees Celsius (e.g., ambient temperatures). In at least oneembodiment, the FBC may achieve the cooling by applying pressurizedblows of cooled inert gas to the coffee fraction while a vibratoryscreen (upon which the coffee fraction is placed) transports the coffeefraction through the FBC. In some embodiments, the cooled coffeefraction may be loaded into a tote bin box and system (e.g., tofacilitate the loading of the coffee fraction into silos for primarypackaging) under inert gas conditions and in the absence of oxygen.

At step 200, the process 1000 includes storing the coffee fraction (insome embodiments, the particles thereof being microencapsulated within acoating that may be hardened, for example, based on oils utilized inprevious processes). In various embodiments, the coffee fraction may bea mass with a variable percentage of coffee particles. In at least oneembodiment, the coffee fraction may be maintained in the package stateuntil utilized in other steps of the process 1000 described herein.

In some embodiments, the coffee fraction may be packaged under a widerange of packing options, including (but not limited to)aluminum-plastic complex, BOPP, paper, plastic, glass, metal orcombinations thereof. In various embodiments, the coffee fraction may bepacked under inert gas, vacuum compensated or vacuum conditions, toprovide and maintain a selected shelf-life (e.g., at least 1 year). Inat least one embodiment, a purpose of the above packaging may be toprotect the coffee fraction from staling or other deleterious activities(e.g., such as those that may arise from coating imperfections that mayoccur during the coating and other processes described herein.

Turning to FIG. 1B, at step 210-C, the process 1000 includes receivingand storing non-coffee ingredients. In one or more embodiments, thenon-coffee ingredients may include, but are not limited to: 1) sugarsand other carbohydrates; 2) reducing sugar counterparts; 3) dairyderivatives; 4) vegetable derivatives; and 5) other non-coffeeingredients. In various embodiments, the non-coffee ingredients may bereceived in and emptied from container and may be stored untilutilization during other steps of the process 1000. In at least oneembodiment, the non-coffee ingredients may be stored under cryogenic orrefrigerated conditions.

At step 240, the process 1000 includes pre-refining sugars and/or othernon-coffee ingredients. In various embodiments, the sugars and/or othernon-coffee ingredients may be retrieved from storage and pre-milled toabout 180 microns.

In at least one embodiment, the pre-milling (or pre-refining) can beperformed in milling equipment including dry or wet impact-type millsequipped with predetermined mesh-sized screens (e.g., 5.5 mm, 6.5 mm,and 8.0 mm). According to one embodiment, the sugars are loaded into themilling equipment and pre-milled to an average particle size of about180 microns. In one or more embodiments, the pre-milling may transform astable, crystalline structure of sugars particles into an unstable,amorphous structure. In various embodiments, the unstable, amorphousstructure provides improved and/or increased thermochemical reactivenessat a surface level of the sugar particles, thereby increasing theirreactivity with amino groups of the amino acids and proteins present inother non-coffee ingredients that are used, in combination with thesugars, to form a non-coffee fraction. In at least one embodiment, thetransformation of the structure of the particles may improve a speedand/or intensity of the Maillard reaction taking place during a conchingor extrusion process described herein.

In various embodiments, up to about 50% by weight of the sugar (e.g., incrystalline structure) is substituted with a quantity of reducing sugarcounterparts to form a sugar blend that is pre-refined as describedherein. In at least one embodiment, the quantity of reducing sugarcounterparts may be selected to provide a sweetness level equivalent tothe substituted mass of the sugar. In one or more embodiments, the sugarblend improves an intensity and speed of a Maillard reaction occurring,for example, in a solid-phase reactor of a conching process. In one ormore embodiments, non-coffee ingredients such as dairy derivatives andvegetable derivatives may be pre-milled. In at least one embodiment,certain non-coffee ingredients may not require to undergo pre-millingstep, as they either are not directly involved in the flavor- andcolor-forming reactions, or may be present in particle sizes that areadequate for the process to take place.

At step 250, the process 1000 includes pre-mixing the pre-refined sugarand other non-coffee ingredients to create a non-coffee pre-mixture. Inat least one embodiment, the pre-refined sugar and other non-coffeeingredients can be combined and mixed at about 20-150 rpm for apredetermined time period up to about 1 hour and while being heated to amelting point of the other non-coffee ingredients, which can be about45-90 degrees Celsius in some embodiments.

In one or more embodiments, the pre-refined sugar and other non-coffeeingredients may be weighed and loaded into a pre-mixer. In one or moreembodiments, the pre-mixer may be a sigma- or ribbon-type blender ormixer configured to operate under vacuum or inert gas conditions and inthe absence of oxygen. In at least one embodiment, the pre-mixerincludes double-helical mixing elements. In various embodiments, thepre-mixer pre-mixes the pre-refined sugar and other non-coffeeingredients at about 20-150 rpm for up to about 1 hour while heating(e.g., via heating elements) the pre-refined sugar and other non-coffeeingredients to a melting point of the other non-coffee ingredients or,in some embodiments, about 45-90 degrees Celsius. In at least oneembodiment, the pre-mixing can be performed in batches with anindividual capacity up to about 15,000 kg (though greater capacities arealso contemplated).

In at least one embodiment, an exemplary formulation of the pre-mixtureformed during pre-mixing includes, but is not limited to: 1) about20-60% natural or RBD fat and/or oil (or cocoa butter substitute orequivalent); 2) about 0-60% pre-refined sugars; 3) about 0.1-60.0%sweeteners; 4) about 0-10% dairy derivatives; 5) about 1-60% proteinand/or carbohydrates; 6) about 0-20% cocoa and/or other chocolateingredients; 7) about 1-30% filler ingredients; 8) about 1-60% otherfats and/or oils; 9) about 1-30% other carbohydrates and/or fibers; 10)up to about 5% additives and/or other micro-ingredients; and 11) up toabout 10% nutrient sources, vitamins, minerals, zoo- and/orphytochemicals, and/or other bioactive ingredients; and 12) up to about5% bio-inactive ingredients.

At step 260, the process 1000 includes dual-extrusion of the non-coffeepre-mixture and recovering aromas therefrom to create a non-coffee mass.In at least one embodiment, the process parameters used to form thenon-coffee mass allow for high-throughput, homogeneous productionformulations. In at least one embodiment, the non-coffee pre-mixture canbe pressurized to about 1-5 bar, heated to a melting point of one ormore of the non-coffee pre-mixture elements (or about 1-90 degreesCelsius in some embodiments), and agitated for about 10 minutes or about5-6 hours, thereby inducing and facilitating the completion of one ormore flavor-forming reactions and forming the non-coffee mass.

In at least one embodiment, by processing the non-coffee pre-mixture asdescribed herein, the flavor-forming reactions can be induced andimproved for reasons including, but not limited to: 1) the non-coffeepre-mixture can demonstrate a residual moisture of less than about 1.5%,thereby favoring the flavor- and color-forming reactions; 2) subjectingthe non-coffee pre-mixture to high-process shearing, impacting, andfriction (from the agitation) and high temperature facilitates theflavor- and color-forming reactions; and 3) a relatively low-fat contentof certain non-coffee pre-mixtures provides for efficient reactivesurfaces in solid particles of the non-coffee pre-mixture that increasesolid phase reactions, thereby intensifying the flavor- andcolor-forming reactions.

In at least one embodiment, to form the non-coffee mass, the non-coffeepre-mixture can be loaded into a feed hopper that feeds a dual-extrudervia an auger feeder equipped with a feed throat that controls thefeeding and/or flow into the extruder. In one or more embodiments, thedual-extruder and components connected thereto can be configured tooperate under inert gas conditions and in the absence of oxygen. In atleast one embodiment, the dual-extruder may be designed to induce theflavor- and color-forming reactions by means of efficient solid phasereaction initiated by heating and agitating the non-coffee pre-mixture.

In various embodiments, the dual-extruder can include, but is notlimited to: 1) a structure including a heavy bed plate where six heavysteel supporting columns may be attached to the dual-extruder (e.g.,four for a main twin barrel and two for other elements of thedual-extruder); 2) a screw driver motor equipped with a frequencyinverter; 3) a reducing gearbox; 4) the feed hopper; 5) a central panelequipped with a number of essential controls including, but not limitedto: A) switches for controlling one or more motors; B) controls of bandheaters; C) thermostat, thermistor, and/or thermocouple controlswitches; D) cryogenic gas expansion valves for a cooling system and/ora piping and instrumentation diagram (PID); E) twin barrel temperaturegauges; 6) heating and cooling element controls; 7) the twin barrelincluding, but not limited to, twin intermeshing screws and efficientsystems for both cooling and heating (e.g., per each section of twinscrews located along an interior of the barrel); 8) pressure gauges formain reaction areas of the twin barrel, the feed hopper, and an armoredrevolving screw changer; 9) rotatable inputs and outputs; 10) meteringpumps for precise dosing of the non-coffee pre-mixture and otheringredients; 11) feed rate inputs and outputs; 12) a screw torquecontrol; 13) a pipe (or other) die including a die temperature control;14) a die temperature, rotary knife cutting system; and 15) other safetycontrols.

In at least one embodiment, the system can precisely control thetemperature of the twin barrel between about 1-90 degrees Celsius (orabout a pre-mixture element melting point). In one or more embodiments,the twin barrel can be pressurized at about 1 to 5 bar.

In various embodiments, the twin barrel may include, but is not limitedto: 1) the twin screws that intermesh to agitate the non-coffeepre-mixture; 2) removable liner for a barrel cover; 3) pressure gaugesand sensors located in key transition processing areas of the twinbarrel; and 4) insertion areas where ingredients can be added directlyin the barrel (e.g., respectively for eventual addition ofvarious/special reactants and for heat-sensitive additives); and 5) anopening to the twin barrel that can be hermetically sealed via thebarrel cover. In at least one embodiment, the twin screws can includemodifications of one or more aspects including, but not limited to: 1) ascrew root; 2) a channel width; 3) a flight; 4) an axial flight width;5) one or more helix angles; 6) a pitch, such as a variable pitch; 7) ascrew clearance; 8) a barrel length; and 9) a barrel diameter. In one ormore embodiments, the twin screws may provide more precise and/orcontrollable solid phase reaction rates, times, and/or temperatures.

In one or more embodiments, a natural vacuum-based degassing port systemmay be included at an edge of the twin-screw barrel. In variousembodiments, the degassing port system may be configured for rapiddegassing and volatilization. In at least one embodiment, the degassingport system may be built-in in a breaker plate from where the non-coffeemass may exit in a closed loop chamber with a stream of inert gas thatmay mix with exhausting gas, and may be directly coupled to afractionation column for off-flavors vent and volatiles (cryogenic)recovery. In at least one embodiment the breaker plate can include, butis not limited to, an extrusion head, the pipe die, a screen pack, andthe rotary knife cutting system.

In various embodiments, the dual extruder can include a secondary vacuumsizing system. In one or more embodiments, the secondary vacuum sizingsystem may be directly coupled at an outlet of the dual extruder. In atleast one embodiment, the secondary vacuum sizing system allows for thesolid phase and flavor-forming reactions to occur under vacuum and alsoallows for the reactions to be cooled with circulation of cooledrefrigerant gas. In at least one embodiment, the secondary vacuum sizingsystem may further facilitate control of end-process reactions and aromarecovery. In at least one embodiment, the dual extruder can include arecovery system (as described herein) that allows for fractionatingdistillation and cryogenic recovery of volatiles, aromas, and othersubstances emitted from the non-coffee pre-mixture during the solidphase and flavor-forming reactions. In one or more embodiments, thevolatiles, aromas, and other substances can be flashed at step 275,cryogenically distilled at step 285, and recovered and stored at step295 for further utilization in other steps of the process 1000.

In at least one embodiment, the non-coffee mass (and particles thereof)can be conched according to one or more processes carried out at step310 and described herein.

At step 320, the process 1000 includes wet milling the non-coffee massto a predetermined particle size of less than about 30 microns, about0.1-40 microns, or below 40 microns under cryogenic and inert gasconditions and in the absence of oxygen. In at least one embodiment, anoutput of the wet milling is a non-coffee fraction. In one or moreembodiments, the wet milling can be performed in a ball mill, such as avertical ball mill, configured for cryogenic and inert gas operation inthe absence of oxygen. In at least one embodiment, the ball mill uses afirst set of milling balls and a second set of milling balls. In atleast one embodiment, the first set of milling balls can include adiameter of about 0.5 mm and the second set of milling balls can includea diameter of about 0.7 mm. According to one embodiment, the non-coffeemass can be loaded into the ball mill (or other suitable millingsystem).

At step 320, the process 1000 includes wet milling the non-coffee massto a predetermined particle size of less than about 30 microns, about0.1-40 microns, or below 40 microns under cryogenic and inert gasconditions and in the absence of oxygen. In at least one embodiment, anoutput of the wet milling is a non-coffee fraction. In one or moreembodiments, the wet milling can be performed in a ball mill, such as avertical ball mill, configured for cryogenic and inert gas operation inthe absence of oxygen. In at least one embodiment, the ball mill uses afirst set of milling balls and a second set of milling balls. In atleast one embodiment, the first set of milling balls can include adiameter of about 0.5 mm and the second set of milling balls can includea diameter of about 0.7 mm. According to one embodiment, the non-coffeemass can be loaded into the ball mill (or other suitable millingsystem).

In various embodiments, the non-coffee mass can be cooled through directcontact with cryogenic, inert gas to about −80 degrees Celsius (or alower temperature). In at least one embodiment, the cooling may only beperformed if the non-coffee mass was conched (e.g., at step 310 orelsewhere). In one or more embodiments, the cryogenic inert gas can besprayed via a spraying mechanism configured inside a screw conveyor thatfeeds the non-coffee mass into the ball mill. In one or moreembodiments, the milling can be initiated when the non-coffee massreaches about −80 degrees Celsius (or a lower temperature) and is in aglassy (brittle) state. In at least one embodiment, the wet milling maybe performed at about 250 rpm for a predetermined milling period ofabout 20 minutes. According to one embodiment, the output non-coffeefraction demonstrates an average particle size less than about 30microns.

At step 330-A, the process 1000 includes storing the non-coffee fractionand fats extracted therefrom (e.g., during conching processes and otherprocesses described herein). In one or more embodiments, non-coffeefraction is pumped to one or more tanks each including low-speedscraped-surface-type stirrers that continuously agitate the non-coffeefraction. In at least one embodiment, the one or more tanks maintain thenon-coffee fraction under inert gas atmosphere at a temperature abovethe melting point of the fats and/or oils used. In one or moreembodiments, the non-coffee fraction may be subsequently dosed usingpositive displacement pump with automatic, pre-set flow controls, andmay be directed to further processes described herein.

At step 190B, the process 1000 includes adding extracted and storedcoffee oil to a blending, homogenization, and plasticization processdescribed herein (and carried out at step 330). In at least oneembodiment, the extracted and stored coffee oil can be pumped into anequipment utilized for blending, homogenizing, and plasticizing thecoffee and non-coffee fractions described herein. According to oneembodiment, the extracted coffee oil can be sprayed onto the coffee andnon-coffee fractions.

At step 340, the process 1000 includes preparing and adding additives tocoffee and/or non-coffee fractions. In at least one embodiment, theadditives may be added to the coffee and non-coffee fractions duringblending, homogenization, and plasticization process described herein(e.g., and carried out at step 330-B). For example, the additives can beadded to a mixer or blender described herein that contains the coffeeand/or non-coffee fractions. In one or more embodiments, additives mayinclude, but are not limited to: 1) salt(s); 2) lecithin(s); 3)polyglycerol polyricinoleate (PGPR); 4) emulsifiers; 5) antioxidants; 6)stabilizers; and 7) various other food-grade additives.

At step 300, the process 1000 includes adding condensed aromas (e.g.,obtained from volatile flashing, distillation, and aroma condensingprocesses performed at steps 275, 285, and 295) to coffee and/ornon-coffee fractions. In at least one embodiment, the condensed aromascan be added to the coffee and non-coffee fractions during blending,homogenization, and plasticization process described herein (e.g., andcarried out at step 330). For example, the additives can be sprayed intoa mixer or blender described herein that contains the coffee and/ornon-coffee fractions.

At step 330, the process 1000 includes blending, homogenizing, andplasticizing the coffee and non-coffee fractions into a composite coffeemass. In one or more embodiments, the blending, homogenizing, andplasticizing can include, but is not limited to: 1) combining apredetermined quantity of the coffee fraction and the non-coffeefraction into a composite mixture; 2) cooling or heating the compositemixture to about 1-70 degrees Celsius; 3) blending the composite mixtureat about 20-150 rpm or about 10-100 rpm; and 4) spraying the compositemixture with additives and/or solutions (e.g., aromas, coffee oil,additives, etc.) at a quantity of about 200% by weight of the coffeefraction (or composite mixture, in some embodiments) for a predeterminedperiod of about 1-100 minutes or about 5-60 minutes.

In various embodiments, the post-blending and/or homogenization may becarried out in one or more blenders, such as ribbon- or sigma-typeblenders (or mixers) configured to operate under inert gas conditionsand in the absence of oxygen and/or under vacuum modified atmosphere(with or without inert gases). In one or more embodiments, one or moreblenders may receive and blend the coffee and non-coffee fractions atspeeds between about 20-150 rpm or about 10-100 rpm utilizingdouble-helices as blending mechanisms. In at least one embodiment,mixers, blenders and/or homogenizers can operate in capacities up toabout 15,000 kg (though greater processing capacities are contemplated).

In various embodiments, the mixers, blenders, and/or homogenizers, mayinclude a built-in spray system device for spraying the additives andsolutions described herein onto the coffee and non-coffee fractionsduring blending, homogenizing, and/or plasticization. In one or moreembodiments, the spray system device may incorporate a variable numberof special double-fluid pressure atomizers-type nozzles (e.g., locatedwithin a hermetically closed processing chamber that includes the coffeeand non-coffee fractions). In at least one embodiment, the spray systemdelivers up to about 200% by weight of the coffee fraction (or compositecoffee mass) in additives and/or solutions, such as those described atsteps 190-B, 300, and 340. In at least one embodiment, the nozzles mayoperate in running cycles of 1-100 minutes or about 5-60 minutes.

In various embodiments, the nozzles may deliver controllable, finelydispersible droplets of the solutions, additives, and/or liquid systems(with an average drop size up to about 100 microns) to the coffee andnon-coffee fractions. In one or more embodiments, one or more blendersinclude internal walls that heat the coffee and non-coffee fractions toa melting point of one or more elements thereof (or about 90 degreesCelsius) and cool the coffee and non-coffee fractions below a meltingpoint of the one or more elements thereof (or about 10 degrees Celsius)during the duration of the blending, homogenizing, and plasticizationprocess (e.g., about 1-100 minutes or about 5-60 minutes).

In one or more embodiments, other complementary and micro-ingredientsmay be added (e.g., following mixing of the other ingredients andadditives) to the composite coffee mass. In at least one embodiment, theother complimentary and micro-ingredients include, but are not limitedto, aromas and flavoring agents, additives, and other suitableingredients including colorants, among others.

In one or more embodiments, one or more blenders include sanitary designfeatures that allow for easy sanitization of the one or more blenders.In some embodiments, the one or more blenders may be assembled in aplatform to facilitate discharge of the composite coffee product intoinert gas locked-in totes, silos, and/or directly to the feeding silosof a packaging line.

In various embodiments, the composite coffee mass may be an edibleproduct imparted with a variable degree of coffee flavor and taste. Inat least one embodiment, the composite coffee mass (e.g., at aplasticization phase) may present a homogeneous solid-like form with avariable viscosity that might be fixed, depending on processingparameters. In one or more embodiments, the composite coffee mass ismixed with suitable fat/oil system combinations according to a plannedend-use. In various embodiments, the composite coffee mass is versatilefor food and beverage applications, such as in formulation of coffeebars, coffee powders, coffee spreads, coffee chunks/morsels/chips, and avariety of applications in refrigerated or frozen desserts, sugar and/orcoffee baked goods, breakfast cereals, power bars, etc.

In one or more embodiments, one or more blenders may include a doublehelicoid rotating shaft, with ancillary paddles and stator devices tofacilitate creation of turbulence during blending of the coffee andnon-coffee fractions. In various embodiments, a processing temperaturecan be from about 1-70, about 1-90 degrees, or about 1 to a meltingpoint of the fat used in Celsius (depending on the fat system used andplanned end-use), which is ensured through heated and/or cooled jacketedwall of the one or more blenders. In one or more embodiments, the mixingequipment may have a variable rotation speed from about 20-150 rpm orabout 10-100 rpm.

At step 350, the process 1000 includes storing the composite coffeemass. In various embodiments, the composite coffee mass may be storedaccording to specifications of quality. In at least one embodiment, thecomposite coffee mass is stored in vertical, sanitary, stainless steeljacketed tanks. In one or more embodiments, the tanks may bewater-heated (e.g., to a temperature up to about 45 degrees Celsius) andmay include a low-speed mixing mechanism that agitates the compositecoffee mass at speeds of about 25-100 rpm. In at least one embodiment,the composite coffee mass may be transferred from the tanks by positivedisplacement pumps to other processes and steps described herein.

At step 355, the process 1000 includes filtering the composite coffeemass to remove contaminants and ensure a high-quality finished product.In one or more embodiments, filtering increases productivity and qualityby improving flow rate, eliminating external contaminant build-up andreducing operating noise and maintenance time. In at least oneembodiment, filtering ensures a purity of the composite coffee mass byavoiding exposure of the composite coffee mass to non-inert atmosphereconditions and/or oxygen.

In various embodiments, a filtration system is used to perform thefiltering, the filtration system may be similar to filtration systemsfrom Russell-Finex Co. of the USA. In one or more embodiments thefiltration system includes, but is not limited to: 1) a positivedisplacement pump that delivers steady flow of a semi-solid liquidpresenting high viscosity at a pressure up to about 15,000 centipoisewithout short time interruption of operation due to partial clogging,while offering a high burst strength of up to 150 psig; 2) a continuous,enclosed-type sanitary filtration system that provides high-qualityoperating conditions, and ensures and maintains a consistently high flowrate and providing a highest quality filtering of the composite coffeemass; 3) a self-cleaning set-up by mechanically scraping collecteddebris from the filter screen with a disc that travels up and down thescreen, parallel to the liquid flow; and 4) a collection chamber (e.g.,at the bottom of the filter system) that automatically purges collecteddebris without halting production in a process that takes up to about0.7 seconds or fewer.

In one or more embodiments, the self-cleaning set-up may provideadditional benefits including, but not limited to: 1) continuousoperation, without interrupting production; 2) improved plant workingconditions due to quieter, enclosed system; 3) virtuallymaintenance-free operations and less frequent replacement of parts, dueto fewer moving parts; 4) operation at a consistently low differentialpressure; and 5) relatively low initial investment.

At step 360, the process 1000 includes transferring (e.g., via pumps oranother transfer mechanism) the filtered composite coffee mass to one ormore tanks (similar to other storage tanks described herein) for storageunder conditions described herein. In various embodiments, the compositecoffee mass can be stored in the tanks until utilization in additionalprocesses, such as packaging operations and/or bulk commercialization.

At step 370, the process 1000 includes transferring (e.g., via pumps oranother transfer mechanism) the composite coffee mass to one or morepre-crystallization storage tanks.

At step 380, the process 1000 includes tempering the composite coffeemass. In some embodiments, whether or not to include step 380 can bebased on a type of fat used. In one or more embodiments, the temperingincludes heating (or cooling) the composite coffee mass to destroyunstable crystals and establish conditions favorable to stable crystalformation. In at least one embodiment, the tempering can be performedvia nucleation techniques.

At step 390-A, the process 1000 includes dosing the composite coffeemass into one or more moulds.

At step 390-B, the process 1000 includes dosing the composite coffeemass onto one or more conveyers.

At step 400-A, the process 1000 includes crystallizing the compositecoffee mass within one or more pre-crystallization moulds. In at leastone embodiment, one or more pre-crystallization moulds can betransported through one or more crystallization tunnels configured toinduce the crystallization of the composite coffee mass (e.g., and alsoenable recovery thereof from the one or more conveyors) within themoulds (e.g., and also enable recovery thereof from the moulds due tocontraction of the composite coffee mass).

At step 400-B, the process 1000 includes crystallizing the dosedcomposite coffee mass atop one or more conveyors. In at least oneembodiment, one or more conveyors transport the dosed composite coffeemass through one or more crystallization tunnels configured to inducethe crystallization of the composite coffee mass. In at least oneembodiment, the crystallized, dosed composite coffee mass can beutilized for composite coffee chunks, morsels, chips, and the like.

At step 410-A, the process 1000 includes demoulding the crystalizedcomposite coffee mass from one or more pre-crystallization moulds.

At step 410-B, the process 1000 includes cutting the crystallized, dosedcomposite coffee mass. In at least one embodiment, one or more conveyorsmay transport the dosed composite coffee mass through one or morecutting systems (e.g., shears, knives, wedges, or other cuttingelements) that cut the dosed composite coffee mass into strips, chunks,or other predetermined shapes (e.g., squares, circles, rectangles,etc.). In some embodiments the composite coffee mass can be crushed orpulverized into powders, chunks, morsels, or other ingredient forms.

At step 390-C, the process 1000 includes collecting excess compositecoffee mass that was not dosed within one or more moulds andde-crystallizing it prior to returning the excess composite coffee massto one or more pre-crystallization tanks described herein (e.g., thetanks utilized at step 370). In one or more embodiments, thede-crystallizing reduces a presence of stable crystals in the temperedcomposite coffee mass, thereby reducing a viscosity of the compositecoffee mass and easing dosing and/or pumping of the tempered compositecoffee mass. According to one embodiment, the tempering andde-crystallizing (of a portion of the tempered mass that is stored andnot immediately dosed) provides for template crystals (e.g.,crystallized fats) that orient formation of new crystals (e.g., duringother and/or subsequent crystallization-related processes).

At step 420, the process 1000 includes performing metal detection on thecomposite coffee mass. In on embodiment, the composite coffee mass canbe passed through one or more metal detectors that generate alerts upondetecting metal in the coffee composite mass. In at least oneembodiment, portions of the composite coffee mass that cause activationof one or more metal detectors may be removed from further processing.

At step 430, the process 1000 includes packaging the composite coffeemass in primary packaging, such as, for example, jars, bottles, andother primary packaging structures.

At step 440, the process 1000 includes packaging the primary-packagedcomposite coffee mass in secondary packaging, such as, for example,boxes, cartons, and other secondary packaging structures.

At step 450, the process 1000 includes performing X-ray inspection onthe secondary-packaged composite coffee mass. In at least oneembodiment, X-ray inspection detects foreign objects and/or otherundesirable elements in the secondary and primary packaging. In variousembodiments, any secondary and/or primary packaging determined, via theX-ray inspection, to include foreign objects and/or other undesirableelements can be removed from further processing and/or retrieve forfurther inspection.

At step 460, the process 1000 includes palletizing the secondary-packagecomposite coffee mass onto one or more pallets for transportation.

At step 470, the process 1000 includes staging the palletized compositecoffee mass for a predetermined staging period up to about 48 hours.

At step 480, the process 1000 includes shipping the staged andpalletized composite coffee mass to one or more predetermined locations.

In one or more embodiments, an alternate process 1000 can be performedand can yield edible sticks, batons, or the like that are (composite)coffee mass-based. In one embodiment, the alternate process 1000 caninclude, but is not limited to: 1) performing steps described herein toobtain a composite coffee mass and/or a coffee fraction; 2) dosing, atstep 390-B, a quantity of coffee mass (or coffee fraction) onto one ormore conveyors; 3) passing the dosed composite coffee mass through apre-crystallization tunnel to partially crystallize the coffee mass suchthat the composite coffee mass can be cut without breaking (in one ormore embodiments, pre-crystallizing may also be utilized to preparechunks, morsels, etc. described herein); 4) cutting, at step 410-B, thepartially-crystallized and dosed composite coffee mass into one or morebatons or sticks (without breaking the composite coffee mass); 5)passing, at step 400-A, the cut composite coffee mass through acrystallization tunnel to complete crystallization of the compositecoffee mass; and 6) performing one or more of steps 390-C-470 tocomplete post-processing and/or packaging of the composite coffee mass.

In at least one embodiment, a second alternate process 1000 can beperformed and can yield bulk coffee mass. In one or more embodiments,the second alternate process 1000 can suspend following performance ofstep 360, and the composite coffee mass stored therein (e.g., in paste,liquid, or solid form) can be packaged for bulk commercialization and/ordelivery (e.g., according to one or more packaging processes describedherein).

In various embodiments, the process 1000 can omit one or more stepsdescribed herein. In at least one embodiment, the process 1000 caninclude

With reference to FIGS. 2A and 2B, shown is a flowchart illustrating apre-processing process 2000 according to various embodiments of thepresent disclosure. At step 2002, the process 2000 includes receivinggreen coffee beans (e.g., in bags) on trucks (or other suitabletransport vehicle or vessel).

At step 2004, the process 2000 includes determining the weight of thegreen coffee beans. In at least one embodiment, determining the weightcan include weighing each truck (or other vehicle or vessel) with thegreen coffee beans thereon and subtracting a known weight of the truckto determine the weight of green coffee beans thereon. In one or moreembodiments, the weight can be recorded and/or utilized in determiningparameters of other processes described herein including, but notlimited to, processing speed, throughput, quantities of additives,ingredients, and other materials utilized during preparation of acomposite coffee mass (or other substance described herein).

At step 2006, the process 2000 includes unloading the green coffeebeans. In at least one embodiment, the green coffee beans can beinitially packed in bags that are unloaded from the trucks (or othervehicles or vessels).

At step 2008, the process 2000 includes storing the bags of green coffeeuntil utilization in other processes described herein.

At step 2010, the process 2000 includes automatically opening andemptying the bags of green coffee into one or more intermediatecontainers (or directly into an intaking feeder).

At step 2012, the process 2000 includes loading the green coffee beansinto one or more intake feeders configured to feed the green coffeebeans to one or more separators.

At step 2014, the process 2000 includes removing coarse impurities fromthe green coffee beans. In at least one embodiment, removing the coarseimpurities can include processing the green coffee through one or moreseparators (such as two-sieve separator-classifiers) that remove thecoarse impurities from the green coffee.

At step 2016, the process 2000 includes moving the coffee beans using aninline transporter/feeder to an aspiration channel. The inlinetransporter/feeder can correspond to any of the feeders described hereinamong other feeders.

At step 2018, the process 2000 includes removing light beans, chaff, anddust from the green coffee beans. In at least one embodiment, removalcan include, but is not limited to, processing the green coffee beansthrough one or more aspiration channels that aspirate out and remove thelight beans, chaff, and dust. According to one embodiment, the removedlight beans may be separated, recovered, and stored for utilization inother coffee manufacturing processes or processes. In variousembodiments, the one or more aspiration channels can output the lightbeans, chaff, and dust to a discharge cyclone and/or bag filters forcollection, recovery, and/or removal from the process 1000.

At step 2022, the process 2000 can include passing theaspiration-treated coffee beans into another inline transporter/feeder.

At step 2024, the process 2000 can include separating and destoning thecoffee beans.

At step 2026, the process 2000 can include passing the destonedseparated coffee beans into another inline transporter/feeder.

At step 2028, the process 2000 can pass the coffee into a vibratorymulti-sieve sorter from the inline transporter/feeder. The vibratorymulti-sieve sorter can sort out multiple size fractions. Material (e.g.,coffee beans) can be moved across the vibratory multi-sieve sorter tosort the materials into different sizes. Other impurities can be sortedout and removed from the materials.

At step 2030, the process 2000 can include the use of a cyclone or bagfilter to remove dust and sand from the coffee beans. The light beansand chaff can move on for further processing at step 2032. The lightbeans and shafts can be separated into partial light beans and courseimpurities, which are discarded at step 2034. The light beans can bepartially recovered for further processing at step 2038. At step 2040,the process 2000 can include removing heavy impurities, such as stonesand pebbles, from the coffee beans. The stones and pebbles can beseparated from the coffee at step 2024.

At step 2042, the coffee output of the vibratory multi-sieve sorter fromstep 2028 can be passed into an in-line transporter/feeder, and into ametal separator at step 2043. The metal separator can correspond to amagnetic drum, where the coffee beans tumbles in the magnetic drum. Anymagnetic impurities among the coffee beans will stick to the magneticdrum rather than moving forward in processing. The metal-free coffeebeans will move into another in-line transporter/feeder at step 2044. Atstep 2046, the process 2000 includes clustering, cutting, and snippingthe beans. Any un-snipped beans can be removed, and beans can bepartially recovered at step 2048.

At step 2050, the process 2000 can include moving the coffee via anin-line transporter/feeder into a continuous washer. The coffee can bewashed in the continuous washer at step 2052. A stainless-steel wiremeshing screen can be used to dewater the coffee at step 2054. At step2056, the beans can be dried in a bean drier. After drying, the beanscan be cooled and stored at step 2057. The water used to wash the beansat step 2052 can be treated firstly at step 2066 and secondly at step2070. The residual water can be discharged at step 2068. The watertreated at step 2070 can be cooled at step 2064 and stored for use atstep 2058. The water can also include replenished water from step 2062.

At step 2072, the coffee beans stored at step 2057 can be sorted intodifferent sizes. In one embodiment, the coffee is sorted into threedifferent sizes. At step 2073 and 2075, the different sizes of coffeebeans can be moved using an in-line transporter/feeder. The beans can bemoved into a density-based bean sorter at step 2074. The density-basedbean sorter can remove beans (or miscellaneous objects) that have thewrong density from the coffee. In some embodiments, the beans can bemoved into intermediate storage at step 2076, and fed back into thein-line transporter/feeder at step 2073 when desired. At step 2078,light beans can be partially recovered. At step 2079, the differentsized beans, all having a density within predetermined ranges, can movefrom the density bean sorter for optical sorting.

At step 2080, an optical sorter can carry out color-based sorting toremove any objects from the coffee that are not within a predeterminedthreshold set of colors and color gradients corresponding to coffeebeans (or another desired material, such as cocoa beans). At step 2082,the beans (or other objects) that do not have the proper color arerejected for further inspection and/or marked for alternative usage. Insome embodiments, in-line transporters/feeders at step 2081 move thecoffee beans to be processed through a peeler-polisher at step 2084. Inthese embodiments at step 2085, the in-line transporters/feeders canmove the coffee beans into in-line weighing scales at step 2086.

At step 2086, the coffee is weighed either from the in-linetransporter/feeders from step 2085. The weighed coffee beans can bestored in intermediary storage silos at step 2088. When furtherprocessing is desired, the coffee beans can be moved from theintermediary storage silos to a bean blending system via in-linetransporter/feeders at step 2089. At step 2090, the process 2000 caninclude blending the beans. The blended beans can be transported viain-line transporter/feeders at step 2091. The blended beans can betransported into a storage silo at step 2092. At step 2093, in-linetransporter/feeders can move the coffee beans to further processing.

With reference to FIGS. 3A and 3B, shown is a flowchart illustrating aprocess 3000 according to various embodiments of the present disclosure.At step 3002, the process includes moving the coffee mass on arefrigerating fluid bed cooler in an inert gas environment. According toone embodiment, the coffee mass can be cooled to a predeterminedpackaging temperature that improve ease of moving and processing thecoffee mass through the process 3000. At step 3004, a vibratory screenerand transporter can screen and transport the coffee mass. Oversizedparticles can be moved to tote-bin loaders at steps 3006 and 3008, whilestandard sized particles can be moved to tote-bin loaders at steps 3014and 3016. The tote-bin loaders 3010 and 3016 can move the coffee mass totote-bins 3012 and 3018. In some embodiments, the coffee mass is storedin tote-bins regardless of particle size. From the tote-bins, the coffeemass can be feed into a tote transporter/feeder system at step 3020.

The coffee mass can be placed into plastic jars using a plastic jarpacking system at step 3022. Plastic jars, lids, and labels can beinfeed to label the packaging at step 3024. A packaged producttransporter/feeder system can move the packaged products at step 3026.Cartons can be feed for packaging at step 3028. Cartons can be erectedand fed for loading at step 3030. The plastic jars containing the coffeemass can be loaded into the cartons at step 3032. An auto-palletizer canpalletize the cartons at step 3034, with pallets being feed at step3040. In some embodiments, pallets can be manually fed or loaded. Thepallets are transported at step 3036. At step 3038, the pallets arestored at a warehouse. At step 3042, the pallets are loaded onto a truckfor transport, and at step 3044, the product is delivered.

With reference to FIG. 4 , shown is an exemplary roasting system 4000,according to one embodiment of the present disclosure. In at least oneembodiment, the roasting system 4000 is configured to perform alloperations under inert gas conditions and in the absence of oxygen.Thus, in various embodiments, coffee beans may be processed through theroasting system 4000 and converted into roasted coffee beans withoutbeing exposed to atmospheric oxygen.

In at least one embodiment, the roasting system 4000 includes a beanloading mechanism 4001 connected to a discharge cyclone 4002. In variousembodiments, the bean loading mechanism 4001 receives clean coffee beansand loads the clean coffee beans into the discharge cyclone 4002. In atleast one embodiment, the discharge cyclone 4002 feeds the clean coffeebeans into an intermediary storage 4003. In various embodiments, theintermediary storage 4003 is connected to a screw feeding system 4004.In one or more embodiments, the intermediary storage 4003 allows for acontrolled flow of the clean coffee beans into the screw feeding system4004. In one or more embodiments, the screw feeding mechanism 4004continuously and controllably rotates to draw the clean coffee beansinto a bean roaster 4005.

In at least one embodiment, the bean roaster 4005 includes, but is notlimited to: 1) a rotary roasting drum 4006 that rotates via an electricmotor 4007, the electric motor 4007 including an electronic controllerfor controlling the rotation; 2) an electric heat source 4008 configuredto provide heat to generate and transfer heat to the rotary roastingdrum 4006; and 3) a discharge device 4009 for expelling roasted coffeebeans from the rotary roasting drum 4006 into a cooling system 5000(FIG. 5 ).

In one or more embodiments, the discharge device 4009 provide adischarge 4010 of the roasted coffee beans that is received by thecooling system 5000 (or another system or process described herein).

In at least one embodiment, the roasting system 4000 operates undervacuum (e.g., about 0.1 bar), and/or atmospheric conditions (1 kg/cm²),and/or medium to high pressure (e.g., up to about 10 kg/sq·cm). In atleast one embodiment, the roasting system 4000 uses heating media. Inone or more embodiments, the heating media may include, but is notlimited to, super-heated steam (SHS) and/or any other suitablepre-heated inert gas, such as nitrogen, carbon dioxide, helium, argon,and the like. In various embodiments, the heating media can also be indirect or indirect contact with biomaterials (such as coffee beans)provided to the roasting system 4000. In at least one embodiment, theheating media can be heated by any type of heating source including, butnot limited to, electric sources, non-ionizing electromagnetic radiationsources, combustion-based sources. In various embodiments, the heatingsource can be located externally to the roasting system 4000, or may belocated internally. According to one embodiment, the non-ionizingelectromagnetic radiation sources can generate non-ionizing radiationincluding, but not limited to, visible radiation, radio-waves, andothers. In various embodiments, the non-ionizing electromagneticradiation sources can be more advantageous as a more efficient anduniform roasting is achieved compared to previous approaches to roastingcoffee beans. In at least one embodiment, the non-ionizingelectromagnetic radiation sources may reduce a risk of exposingbiomaterials (e.g., coffee beans) to oxygen during roasting.

In various embodiments, the roasting system 4000 includes an inert gasdistribution pipeline 4011 that delivers inert gas throughout the system4000. For example, the distribution pipeline 4011 can provide inert gasto the bean roaster 4005, thereby allowing for roasting of the cleancoffee beans under inert gas conditions and in the absence of oxygen. Inat least one embodiment, the distribution pipeline 4011 delivers theinert gas to an input of the bean roaster 4005 and receives the inertgas from an output of the bean roaster 4005 (e.g., following movement ofthe inert gas therein).

In at least one embodiment, the distribution pipeline 4011 passes theinert gas from the output of the bean roaster 4005 through one or moreelements including, but not limited to: 1) a HEPA filter 4016 thatfilters off-products and other substances from the inert gas; 2) anexhaust fan 4017 that accelerates the inert gas and maintains correctdirectionality in the flow of the inert gas through the distributionpipeline 4011; 3) a cyclone 4018 that discharges dust and/or chaff fromthe inert gas; 4) a bag filter 4019 that discharges dust and/or chafffrom the inert gas; 5) a second HEPA filter 4020 that removes additionaloff-products and substances from the inert gas; 6) a heat exchanger 4012that cools the inert gas; 7) an inert gas primary tank 4022 thatsupplies the inert gas to the roasting system 4000 and other systems andprocesses described herein; 8) a moisture condenser 4015 that condensesvolatiles, aromas, and other substances (e.g., emitted from the cleancoffee beans during roasting) out of the inert gas and into liquid form(e.g., water containing the volatiles, aromas, and other substances); 9)a coalescent condenser 4014 that recovers and separates the liquid form(containing the condensed volatiles, aromas, and other substances) fromthe inert gas and outputs the liquid form to recovery and extractionprocesses described herein); 10) one or more inert gas fans 4013 thataccelerate the inert gas through the distribution pipeline 4011; and 11)a second heat exchanger 4021 that heats the inert gas prior to thedistribution pipeline 4011 delivering the inert gas to the input of thebean roaster 4005.

With reference to FIG. 5 shown is an exemplary cooling system 5000,according to one embodiment of the present disclosure. In at least oneembodiment, the cooling system 5000 is configured to perform alloperations under inert gas conditions and in the absence of oxygen.Thus, in various embodiments, roasted coffee beans may be processedthrough the cooling system 5000 without being exposed to atmosphericoxygen.

In at least one embodiment, the cooling system 5000 includes a beanloading mechanism 5001 connected to a discharge cyclone 5002. In variousembodiments, the bean loading mechanism 5001 receives and loads roastedcoffee beans into the discharge cyclone 5002. In at least oneembodiment, the discharge cyclone 5002 feeds the roasted coffee beansinto an intermediary storage 5003. In various embodiments, the loadintermediary storage 5003 is connected to a screw feeding system 5004.In one or more embodiments, the intermediary storage 5003 allows for acontrolled flow of the roasted coffee beans into the screw feedingsystem 5004. In one or more embodiments, the screw feeding mechanism5004 continuously and controllably rotates to draw the roasted coffeebeans into a two-stage inert gas cooler 5005. In at least oneembodiment, the inert gas cooler 5005 includes a torrefacto andquenching system configured to perform torrefacto and quenchingprocesses described herein.

In one or more embodiments, the inert gas cooler 5005 includes coolingelements configured to cool the roasted coffee beans according to one ormore cooling processes described herein. In one or more embodiments, theinert gas cooler 5005 can blow cooled inert gas throughout an internalchamber and/or through a fluid bed that includes the roasted coffeebeans. In one or more embodiments, the inert gas cooler 5005 can coolthe roasted coffee beans in the first stage. In at least one embodiment,the torrefacto and quenching system applies, in the second stage, atorrefacto and/or quenching process to the roasted coffee beans.

In at least one embodiment, in the first stage the torrefacto andquenching system may receive and spray only the torrefacto solution(e.g., sugar solution) and the inert gas cooler 5005 may suspendpre-cooling, cooling, and/or post-cooling processes. In one or moreembodiments, in a second stage, the inert gas cooler 5005 can carry outthe pre-cooling, cooling, and/or post-cooling processes to cool andquench the roasted coffee beans.

In various embodiments, the first stage and the second stage may occursequentially, simultaneously, or in reverse.

In one or more embodiments, the torrefacto and quenching system of theinert gas cooler 5000 includes spraying mechanisms that receive thesugar solution (described herein) from an enclosed coating boiler 5008.In one or more embodiments, the enclosed coating boiler 5008 receivesthe sugar solution and/or water from one or more tanks 5007 and heatsthe sugar solution to about 90 degrees Celsius. In various embodiments,a positive displacement dosing pump 5009 pumps the sugar solution fromthe enclosed coating boiler 5008 to one or more spraying nozzles of thespray mechanism. In at least one embodiment, one or more sprayingnozzles spray the sugar solution onto the roasted coffee beans accordingto torrefacto and quenching processes described herein. In one or moreembodiments, the positive displacement dosing pump 5009 can beconfigured to pump cooled or heated water to the one or more sprayingnozzles that spray the water onto the roasted coffee beans, therebyquenching thermolysis reactions thereof.

In one or more embodiments, the cooling system 5000 includes a dischargescrew 5006 that discharges the roasted beans 4024 from the inert gascool 5005 following completion of pre-cooling, post-cooling, torrefacto,and/or quenching processes therein. In at least one embodiment, thedischarge screw 5006 can discharge the roasted beans 4024 to one or morepre-, dry-, and/or wet-milling processes described herein.

In various embodiments, the cooling system 5000 includes an inert gasdistribution pipeline 5010 that delivers inert gas throughout thecooling system 5000. For example, the distribution pipeline 5010 canprovide inert gas to the inert gas cooler 5005, thereby allowing forpre-cooling, cooling, torrefacto application, and/or quenching of theroasted coffee beans under inert gas conditions and in the absence ofoxygen. In at least one embodiment, the distribution pipeline 5010delivers the inert gas to an input of the inert gas cooler 5005 andreceives the inert gas from an output of the inert gas cooler 5005(e.g., following movement of the inert gas therein).

In at least one embodiment, the distribution pipeline 5010 passes theinert gas from the output of the inert gas cooler 5005 through one ormore elements including, but not limited to: 1) a HEPA filter 5011 thatfilters off-products and other substances from the inert gas; 2) aninert gas exhaust fan 5012 that accelerates the inert gas and maintainscorrect directionality in the flow of the inert gas through thedistribution pipeline 5010; 3) a separation cyclone 5013 that dischargesdust and/or chaff from the inert gas; 4) a bag filter 5014 thatdischarges dust and/or chaff from the inert gas; 5) a second HEPA filter5015 that removes additional off-products and substances from the inertgas; 6) an inert gas fan 5016 that accelerates the inert gas through thedistribution pipeline 5010 and maintains correct directionality in theflow thereof; 7) a heat exchanger 5017 that cools the inert gas; 8) aprimary inert gas tank 5018 that supplies the inert gas to the coolingsystem 5000, and other systems and processes described herein; 9) acondenser 5019 that condenses volatiles, aromas, and other substances(e.g., emitted from the clean coffee beans during roasting) out of theinert gas and into liquid form (e.g., water containing the volatiles,aromas, and other substances); 10) a coalescent condenser and filter5020 that recovers and separates the liquid containing the condensedvolatiles, aromas, and other substances from the inert gas and outputsthe liquid part to recovery and extraction processes described herein;11) one or more inert gas fans 5021 that accelerate the inert gasthrough the distribution pipeline 5010; and 12) a second heat exchanger5022 that heats the inert gas prior to the distribution pipeline 5010delivering the inert gas to the input of the inert gas cooler 5005.

In a particular embodiment, the cooling system 5000 includes a gasexhauster (or extractor) in a closed or semi-closed loop to create acontrolled depression of the system and (via synchronization with thegas flux blowing through the screen of the fluid bed of the inert gascooler 5000) provide enhanced control of the fluid bed cooling effect.In particular embodiments, the gas exhauster can provide for moreprecise and accurate control of the final post-roasting moisture leveland more efficient cooling, thereby providing reduced cooling times.

In at least one embodiment, the cooling system 5000 includes closed-loopsystems that synchronize outflow of the inert gas from the inert gascooler 5005 to the separation cyclone and condenser with the inflow offresh inert gas into the inert gas cooler 5005. In one or moreembodiments, the fresh inert gas transfers heat and mass (such as waterunder latent heat of evaporation) from the roasted coffee beans into theinert gas. In one or more embodiments, the fresh inert gas can flow, viathe distribution pipeline 5010, to the condenser 5019 to be dehumidifiedunder cryogenic conditions (e.g., and for recovery and/or discharge ofdust, chaff, and other masses therefrom). In at least one embodiment,the cooling system 5000 may re-inject part of the dehumidified freshinert gas to compensate any inert gas losses and to maintain a balancedheat and mass transfer.

With reference to FIG. 6 , shown is a conche, distillation, andcondensation (CDC) system 6000, according to one embodiment of thepresent disclosure. In at least one embodiment, the CDC system 6000 isconfigured to perform all operations under inert gas conditions and inthe absence of oxygen. Thus, in various embodiments, wet-milled coffee(e.g., obtained from dry-milled, SCFE-treated, roasted coffee beans) maybe processed through the CDC system 6000 without being exposed toatmospheric oxygen.

In at least one embodiment, the CDC system 6000 includes a bean loadingmechanism 6001 connected to a discharge cyclone 6002. In variousembodiments, the bean loading mechanism 6001 receives and loadswet-milled coffee into the discharge cyclone 6002. In at least oneembodiment, the discharge cyclone 6002 feeds the wet-milled coffee intoa load intermediary storage 6003. In various embodiments, the loadintermediary storage 6003 is connected to a screw feeding system 6004.In one or more embodiments, the load intermediary storage 6003 allowsfor a controlled flow of the wet-milled coffee into the screw feedingsystem 6004. In one or more embodiments, the screw feeding mechanism6004 continuously and controllably rotates to draw the wet-milled coffeeinto a solid phase reactor 6005.

In one or more embodiments, the solid phase reactor 6005 can conche thewet-milled coffee according to parameters and conditions describedherein. In one or more embodiments, a conche 6006 can be attached to thesolid-phase reactor 6005. In various embodiments, the conche 6006 canconche the wet-milled coffee (as described herein). In at least oneembodiment, both the solid-phase reactor 6005 and the conche 6006 canconche the wet-milled coffee. In one or more alternate embodiments, onlythe conche 6006 conches the wet-milled coffee. In at least one alternateembodiment, only the solid-phase reactor 6005 conches the wet-milledcoffee. According to one embodiment, the solid-phase reactor 6005 canperform a first portion of a conching process described herein, and theconche 6006 can perform a second portion of the conching process. Thus,in at least one embodiment, the solid-phase reactor 6005 and conche 6006may be a single unit with internal stages for conching the wet-milledcoffee.

In one or more embodiments, as described herein, conching processes cancause emission of volatiles, aromas, and other substances into the inertgas being pumped through the CDC system 6000 (and/or other systems). Inat least one embodiment, an aroma fractionation column 6009 can beattached to the conche 6006 (or solid-phase reactor 6005) and canreceive inert gases from conching processes. In various embodiments, thearoma fractionation column 6009 separates out various aromas volatilesfrom the inert gas based on boiling temperatures thereof.

In at least one embodiment, an inert gas distribution pipeline 6025transports inert gas into and out of the solid-phase reactor 6005 and/orthe conche 6006, and throughout elements of the CDC system 6000including, but not limited to: 1) the aroma fractionation column 6009;2) a condenser 6010 that condenses the inert gas (e.g., and/or condensesvolatiles, aromas, and/or other substances out of the inert gas); 3) aphase separator 6011 that separates an aqueous phase of the inert gasfrom an organic phase of the inert gas; 4) a cryogenic aroma collector6012 that receives the aqueous phase or the organic phase of the inertgas (e.g., for recovery processes described herein); 5) a vacuum pump6013 that accelerates the inert gas through the distribution pipeline6025 and prevents backflow of the inert gas; 6) a solid-phase separator6014 that separates the solid phase (e.g., containing biomaterials (suchas coffee particles) out of the inert gas and discharge the solid phasefrom the CDC system 6000; 7) a post-filtration unit 6015 that filtersfine materials out of the inert gas; 8) a HEPA filter 6016 that removesoff-products and substances from the inert gas; 9) an exhaust fan 6017that accelerates the inert gas through the distribution pipeline 6025and maintains correct directionality in the flow thereof; 10) an inertgas heater 6018 that heats the inert gas; 11) an inert gas primary tank6019 that supplies the inert gas to the CDC system 6000 and othersystems and processes described herein; 12) a condenser 6020 thatcondenses volatiles, aromas, and other substances (e.g., emitted fromthe wet-milled coffee during conching) out of the inert gas and intoliquid form (e.g., water containing the volatiles, aromas, and othersubstances); 13) a cryogenic condensing unit 6022 that recovers andseparates the liquid containing the condensed volatiles, aromas, andother substances from the inert gas and outputs the liquid part torecovery and extraction processes described herein; 14) one or moreinert gas pumps 6022 that accelerate the inert gas through thedistribution pipeline 6025; and 15) a heat exchanger 6022 that heats theinert gas prior to the distribution pipeline 5010 delivering the inertgas to the input of the solid phase reactor 6005 and/or conche 6006.

With reference to FIG. 7 , shown is a drying, agglomeration, and coating(DAC) system 7000, according to one embodiment of the presentdisclosure. In various embodiments, the DAC system 7000 can be utilizedto perform one or more drying, agglomeration, coating, andmicroencapsulation processes described herein. In at least oneembodiment, the DAC system 7000 is configured to perform all operationsunder inert gas conditions and in the absence of oxygen. Thus, invarious embodiments, wet-milled coffee (e.g., obtained from dry-milled,SCFE-treated, roasted beans 4024, etc.) may be processed through the DACsystem 7000 without being exposed to atmospheric oxygen.

In at least one embodiment, the DAC system 7000 includes a bean loadingmechanism 7001 connected to a discharge cyclone 7002. In variousembodiments, the bean loading mechanism 7001 receives and loadswet-milled coffee into the discharge cyclone 7002. In at least oneembodiment, the discharge cyclone 7002 feeds the wet-milled coffee intoa load intermediary storage 7003. In various embodiments, the loadintermediary storage 7003 is connected to a screw feeding system 7004.In one or more embodiments, the load intermediary storage 7003 allowsfor a controlled flow of the wet-milled coffee into the screw feedingsystem 7004. In one or more embodiments, the screw feeding mechanism7004 continuously and controllably rotates to draw the wet-milled coffeeinto a fluid bed drier (FBD) unit 7005.

According to one embodiment, the FBD unit 7005 include one or morestages (for example, 4 stages). In various embodiments, the FBD unit7005 can be configured to operate on a continuous basis, under inert gasconditions, and/or in the absence of oxygen. In various embodiments, theFBD unit 7005 performs drying, agglomerating, and coating processes asdescribed herein. In one example, the FBD unit 7005 performs the drying,agglomerating, and coating processes included in step 195 (and/or othersteps) of the coffee manufacturing process 1000 described herein.

In one or more embodiments, the DAC system 7000 includes sprayingmechanisms that receive agglomerating and coating solution (describedherein) from an enclosed coating boiler 7008. In one or moreembodiments, the enclosed coating boiler 7008 receives the agglomeratingand coating solution and/or water from one or more tanks 7007 and heatsthe agglomerating and coating solution to a melting point of one or morefats or to, which can be about 90 degrees Celsius. In variousembodiments, a positive displacement dosing pump 7009 pumps theagglomerating and coating solution from the enclosed coating boiler 7008to one or more spraying nozzles of the spray mechanism. In at least oneembodiment, the one or more spraying nozzles spray the agglomerating andcoating solution onto the wet-milled coffee according to agglomeratingand coating processes described herein.

In one or more embodiments, the DAC system 7000 includes a dischargescrew 7006 that discharges the wet-milled coffee from the FBD unit 7005following completion of drying, agglomerating, and/or cooling processestherein. In at least one embodiment, the discharge screw 7006 candischarge the wet-milled coffee to one or more conching, blending,homogenization, plasticization, filtering, dosing, crystallizing, and/orpackaging processes described herein.

In various embodiments, the DAC system 7000 includes an inert gasdistribution pipeline 7010 that delivers inert gas throughout thecooling system 7000. For example, the distribution pipeline 7010 canprovide inert gas to the FBD unit 7005, thereby allowing for drying,agglomerating and/or coating of the wet-milled coffee under inert gasconditions and in the absence of oxygen. In at least one embodiment, thedistribution pipeline 7010 delivers the inert gas to an input of the FBDunit 7005 and receives the inert gas from an output of the FBD unit 7005(e.g., following movement of the inert gas therein).

In at least one embodiment, the distribution pipeline 7010 passes theinert gas from the output of the FBD 7005 through one or more elementsincluding, but not limited to: 1) a HEPA filter 7011 that filtersoff-products and other substances from the inert gas; 2) an inert gasexhaust fan 7012 that accelerates the inert gas and maintains correctdirectionality in the flow of the inert gas through the distributionpipeline 7010; 3) a separation cyclone 7013 that discharges dust and/orchaff from the inert gas; 4) a filter bag tank 7014 that discharges dustand/or chaff from the inert gas; 5) a second HEPA filter 7015 thatremoves additional off-products and substances from the inert gas; 6) aninert gas fan 7016 that accelerates the inert gas through thedistribution pipeline 7010 and maintains correct directionality in theflow thereof; 7) a heat exchanger 7017 that cools the inert gas; 8) aprimary inert gas tank 7018 that supplies the inert gas to the DACsystem 7000 and other systems and processes described herein; 9) acondenser 7019 that condenses volatiles, aromas, and other substances(e.g., emitted from the wet-milled coffee during drying, agglomerating,and/or coating) out of the inert gas and into liquid form (e.g., watercontaining the volatiles, aromas, and other substances); 10) acoalescent condenser and filter 7020 that recovers and separates theliquid containing the condensed volatiles, aromas, and other substancesfrom the inert gas, and outputs the liquid part to recovery andextraction processes described herein; 11) one or more inert gas fans7021 that accelerate the inert gas through the distribution pipeline7010; 12) a second heat exchanger 7022 that heats the inert gas prior tothe distribution pipeline 7010 delivering the inert gas to the input ofthe inert FBD unit 7005; 13) a post-condenser 7023 that condensesvolatiles, aromas, and other substances out of the inert gas; 14) asecondary heat exchanger 7024 that heats the inert gas prior to thedistribution pipeline 7010 delivering the inert gas to the input of theFBD unit 7005; and 15) a third HEPA filter 7025 that removesparticulates, dust, and other contaminants from the inert gas beforedelivery into the FBD unit 7005

Exemplary Formulations

In one or more embodiments, provided herein are exemplary formulationsfor coffee mass (or coffee fraction-based) products. In at least oneembodiment, as used herein, “coffee liquor” can generally refer to acoffee mass (or coffee fraction) ingredient, thus, coffee liquor can beused interchangeably herein with the coffee mass (or coffee fraction)described herein. Thus, in various embodiments coffee liquor, coffeemass, and coffee fraction can refer to a liquid, solid, or hybridthereof (e.g., a paste) prepared, as described herein, from coffeeingredients and other ingredients.

In various embodiments, the formulations described herein (and coffeeliquor ingredient included therein) can be produced under inertconditions and in the absence of oxygen, or may be produced (asdescribed herein) in the presence of oxygen (e.g., all other processesoccurring as described herein, under ambient atmosphere conditions).

In at least one embodiment, to produce chunks, morsels, batons, sticks,and/or other products, processes described herein can be performed atlower temperatures to avoid premature melting of the chunks, morsels,batons, sticks, and/or other products.

According to one embodiment, dairy ingredients can include equivalentnon-dairy substitute ingredients, such as, for example, plant-baseddairy alternatives. In one or more embodiments, the formulationsdescribed herein can include other biomaterials (e.g., in addition to orsubstitution of other ingredients), such as teas, flavoring agents,spices, and other biomaterials.

TABLE 1 Exemplary formulation for a coffee mass product. Fat-BasedGanache Ingredient % Weight Sugar 45.0-55.0 Lecithin (any) 0.1-2.0 DairyIngredients  9.5-25.0 Coffee Mass  5.0-15.0 Vegetable Oil 10.0-20.0Vegetable Fat  9.0-25.0

Table 1 includes an exemplary formulation for a coffee-based product, inparticular, a fat-based ganache. In one embodiment, the exemplaryfat-based ganache formulation includes approximately: 45.0% weightsugar; 0.5% weight lecithin; 16.0% weight dairy ingredients; 10.0%weight coffee mass (as produced/described herein); 15.5% weightvegetable oil; and 14.5% weight vegetable fat.

According to a particular embodiment, the exemplary fat-based ganacheformulation includes approximately: 45.0-48.0% weight sugar; 0.1-2.0%weight lecithin; 12.0-19.0% weight dairy ingredients; 6.0-12.0% weightcoffee mass (as produced/described herein); 14.0-17.0% weight vegetableoil; and 15.0-18.0% weight vegetable fat.

TABLE 2 Exemplary formulation for a coffee mass product. Chunks 1Ingredient % Weight Sugar 25.0-40.0  Lecithin (any) 0.1-2.0  DairyIngredients 8.0-32.0 Cocoa Butter 25.0-40.0  Coffee Mass 5.0-15.0Vegetable Fat 1.0-10.0 Vegetable Oil 1.0-10.0

Table 2 includes an exemplary formulation for a coffee-based product, inparticular, a first formulation for chunks. In one embodiment, theexemplary first formulation for chunks includes approximately: 33.0%weight sugar; 0.5% weight lecithin; 20.5% weight dairy ingredients;35.0% weight cocoa butter; 6.5% weight coffee mass (asproduced/described herein); 4.0% weight vegetable fat; and 4.0% weightvegetable oil.

According to a particular embodiment, the exemplary first formulationfor chunks includes approximately: 31.0-34.0% weight refined sugar;0.1-2.0% weight lecithin; 13.5-21.5% weight dairy ingredients;33.0-36.0% weight cocoa butter; 5.0-8.0% weight coffee mass (asproduced/described herein); 3.0-5.0% weight vegetable fat; and 3.0-5.0%weight vegetable oil.

TABLE 3 Exemplary formulation for a coffee mass product. Chunks 2Ingredient % Weight Sugar 30.0-45.0 Cocoa Butter  5.0-15.0 Specialty Fat15.0-25.0 Lecithin (any) 0.1-2.0 Dairy Ingredients 10.0-20.0 Bulkingredient (e.g., maltodextrin)  5.0-10.0 Coffee Mass  5.0-15.0

Table 3 includes an exemplary formulation for a coffee-based product, inparticular, a second formulation for chunks. In one embodiment, theexemplary second formulation for chunks includes approximately: 38.0%weight sugar; 7.5% weight cocoa butter; 22.0% weight specialty fat; 0.5%weight lecithin; 17.1% weight dairy ingredients; 7.4% weight bulkingredient (e.g., maltodextrin); and 7.5% weight coffee mass (asproduced/described herein).

According to a particular embodiment, the exemplary second formulationfor chunks includes approximately: 36.0-39.0% weight sugar; 6.0-10.0%weight cocoa butter; 20.0-24.0% weight specialty fat; 0.1-2.0% weightlecithin; 14.0-20.0% weight dairy ingredients; 6.0-8.0% weight bulkingredient (e.g., maltodextrin); and 6.0-10.0% weight coffee mass (asproduced/described herein).

TABLE 4 Exemplary formulation for a coffee mass product. Chunks 3Ingredient % Weight Sugar 25.0-35.0 Cocoa Butter 25.0-35.0 Inulin10.0-20.0 Lecithin (any) 0.1-2.0 Dairy Ingredients 10.0-20.0 Coffee Mass 5.0-15.0

Table 4 includes an exemplary formulation for a coffee-based product, inparticular, a third formulation for chunks. In one embodiment, theexemplary third formulation for chunks includes approximately: 30.0%weight sugar; 30.0% weight cocoa butter; 15.0% weight inulin; 0.5%weight lecithin; 16.0% weight dairy ingredients; and 8.5% weight coffeemass (as produced/described herein).

According to a particular embodiment, the exemplary third formulationfor chunks includes approximately: 29.0-32.0% weight sugar; 29.0-32.0%weight cocoa butter; 13.0-16.0% weight inulin; 0.1-2.0% weight lecithin;14.0-20.0% weight dairy ingredients; and 6.0-9.0% weight coffee mass (asproduced/described herein).

TABLE 5 Exemplary formulation for a coffee mass product. Chunks 4Ingredient % Weight Cocoa Mass 1.0-7.0  Cocoa Butter 7.0-15.0 CocoaPowder 5.0-10.0 Dairy Ingredients 3.0-21.0 Sugar 30.0-50.0  Lecithin(any) 0.1-2.0  Specialty Fat 7.0-15.0 Coffee Mass 5.0-12.0

Table 5 includes an exemplary formulation for a coffee-based product, inparticular, a fourth formulation for chunks. In one embodiment, theexemplary fourth formulation for chunks includes approximately: 3.5%weight cocoa mass; 12.0% weight cocoa butter; 6.5% weight cocoa powder;12.0% weight dairy; 44.5% weight sugar; 0.5% weight lecithin; 12.0%weight specialty fat; and 9.0% weight coffee mass (as produced/describedherein).

According to a particular embodiment, the exemplary fourth formulationfor chunks includes approximately: 2.0-5.0% weight cocoa mass;11.0-13.0% weight cocoa butter; 5.0-8.0% weight cocoa powder; 6.0-11.0%weight dairy ingredients; 43.0-46.0% weight sugar; 0.1-2.0% weightlecithin; 11.0-13.0% weight specialty fat; and 7.0-10.0% weight coffeemass (as produced/described herein).

TABLE 6 Exemplary formulation for a coffee mass product. Chunks 5Ingredient % Weight Refined Sugar 30.0-45.0 Specialty Fat 25.0-35.0Lecithin (any) 0.1-2.0 Dairy Ingredients 10.0-20.0 Bulk ingredient(e.g., maltodextrin)  5.0-10.0 Coffee Mass  5.0-10.0

Table 6 includes an exemplary formulation for a coffee-based product, inparticular, a fifth formulation for chunks. In one embodiment, theexemplary pieces formulation includes approximately: 37.5% weight sugar;30.5% weight specialty fat; 0.5% weight lecithin; 17.0% weight dairyingredients; 7.0% weight bulk ingredient (e.g., maltodextrin); 7.5%weight coffee mass (as produced/described herein).

According to a particular embodiment, the exemplary pieces formulationincludes approximately: 36.0-39.0% weight sugar; 29.0-32.0% weightspecialty fat; 0.1-2.0% weight lecithin; 14.0-20.0% weight dairyingredients; 6.0-8.0% weight bulk ingredient (e.g., maltodextrin); and6.0-9.0% weight coffee mass (as produced/described herein).

TABLE 7 Exemplary formulation for a coffee mass product. Icing/FrostingIngredient % Weight Sugar 37.0-50.0  Specialty Fat 7.0-15.0 Lecithin(any) 0.1-2.0  Dairy Ingredients 7.5-27.0 Coffee Mass 5.0-10.0 VegetableFat 5.0-10.0 Vegetable Oil 10.0-25.0 

Table 7 includes an exemplary formulation for a coffee-based product, inparticular, icing/frosting. In one embodiment, the exemplaryicing/frosting formulation includes approximately: 43.5% weight sugar;12.0% weight specialty fat; 0.5% weight lecithin; 15.5% weight dairyingredients; 7.0% weight coffee mass (as produced/described herein);7.5% weight vegetable fat; and 14.0% weight vegetable oil.

According to a particular embodiment, the exemplary icing formulationincludes approximately: 42.0-45.0% weight sugar; 10.0-13.0% weightspecialty fat; 0.1-2.0% weight lecithin; 10.1-21.5% weight dairyingredients; 6.0-9.0% weight coffee mass (as produced/described herein);6.0-9.0% weight vegetable fat; and 11.0-14.0% weight vegetable oil.

TABLE 8 Exemplary formulation for a coffee mass product. Coating 1Ingredient % Weight Sugar 40.0-50.0 Specialty Fat 25.0-35.0 Lecithin(any) 0.1-2.0 Dairy Ingredients  3.0-15.0 Bulk ingredient (e.g.,maltodextrin) 1.0-7.0 Coffee Mass 10.0-15.0

Table 8 includes an exemplary formulation for a coffee-based product, inparticular, a first coating. In one embodiment, the exemplary firstcoating formulation includes approximately: 44.5% weight sugar; 27.5%weight specialty fat; 0.5% weight lecithin; 9.5% weight dairyingredients; 4.5% weight bulk ingredient (e.g., maltodextrin); and 13.5%weight coffee mass (as produced/described herein).

According to a particular embodiment, the exemplary first coatingincludes approximately: 43.0-46.0% weight sugar; 26.0-29.0% weightspecialty fat; 0.1-2.0% weight lecithin; 7.0-13.0% weight dairyingredients; 3.0-6.0% weight bulk ingredient (e.g., maltodextrin); and12.0-15.0% weight coffee mass (as produced/described herein).

TABLE 9 Exemplary formulation for a coffee mass product. Coating 2Ingredient % Weight Sugar 30.0-45.0 Specialty Fat 25.0-35.0 Lecithin(any) 0.1-2.0 Dairy Ingredients  9.0-22.0 Cocoa Powder  5.0-15.0 CoffeeMass  5.0-15.0

Table 9 includes an exemplary formulation for a coffee-based product, inparticular, a second coating. In one embodiment, the exemplary secondcoating formulation includes approximately: 35.5% weight sugar; 30.0%weight specialty fat; 0.5% weight lecithin; 16.0% weight dairyingredients; 9.0% weight cocoa powder; and 9.0% weight coffee mass (asproduced/described herein).

According to a particular embodiment, the exemplary second coatingincludes approximately: 34.0-37.0% weight sugar; 29.0-32.0% weightspecialty fat; 0.1-2.0% weight lecithin; 14.0-20.0% weight dairyingredients; 8.0-11.0% weight cocoa powder; and 8.0-11.0% weight coffeemass (as produced/described herein).

TABLE 10 Exemplary formulation for a coffee mass product. Coating 3Ingredient % Weight Sugar 20.0-30.0  Specialty Fat 25.0-35.0  Lecithin(any) 0.1-2.0  Dairy Ingredients 9.0-22.0 Cocoa Powder 5.0-15.0 Inulin5.0-15.0 Coffee Mass 5.0-15.0

Table 10 includes an exemplary formulation for a coffee-based product,in particular, a third coating. In one embodiment, the exemplary thirdcoating formulation includes approximately: 25.5% weight sugar; 30.0%weight specialty fat; 0.5% weight lecithin; 16.0% weight dairy; 9.0%weight cocoa powder; 10.0% weight inulin; and 9.0% weight coffee mass(as produced/described herein).

According to a particular embodiment, the exemplary third coatingformulation includes approximately: 24.0-27.0% weight sugar; 29.0-32.0%weight specialty fat; 0.1-2.0% weight lecithin; 14.0-20.0% weight dairyingredients; 8.0-11.0% weight cocoa powder; 9.0-12.0% weight inulin; and8.0-11.0% weight coffee mass (as produced/described herein).

Exemplary Multi-Stream Process

In at least one embodiment, particular biomaterial (e.g., coffee)processing steps and non-particular biomaterial (e.g., non-coffeematerial) processing steps may be separated into two or more separatestreams of processing (e.g., dual-stream, tri-stream, etc.). In variousembodiments, coffee and non-coffee streams may be separated at thebeginning of processing (or at an early processing step), and the coffeeand non-coffee streams may be joined (or the materials produced thereinmay be combined) at later steps in the process (e.g., the end of eachstream). According to various aspects of the present disclosure,combination of the coffee and non-coffee streams yields a coffee-basedmass that may be shaped into a moulded product or any other form.

As will be understood from discussions herein, in various embodiments,preparation of composite coffee products may require incorporation of avariety of ingredients and additives (e.g., depending on the proposedutilization of the finished products). In one or more embodiments, awide variety of food and beverage products could be prepared usingsingle coffee mass, using processing technology employed for chocolateproducts, but heavily modified (e.g., as described herein) due topresent technology being very different in many aspects (e.g., given thenature of coffee and/or coffee precursor components). In at least oneembodiment, the coffee ingredients described herein (e.g., encapsulatedand milled roast and ground coffee, coffee liquor, etc.) may be combinedin variable proportions with a plurality of functional food ingredientsincluding, but not limited to, vegetable and animal ingredients, andderivatives thereof, thereby forming one or more consumableformulations. For example, one or more formulations may include, but arenot limited to: 1) baked or fried goods; 2) beverages; 3) cereals; 4)yogurts; 5) cheesecakes and other refrigerated desserts; 6) ice creamsand other frozen desserts; 7) custards, gelatins and fillings, or thelike; 8) toppings; 9) fruits; 10) nuts (whether roasted, coated, orotherwise); 11) syrups and spreads, or the like; 12) dressings, saucesand condiments, or the like; 13) confectionery fruits and/or pannedproducts; 14) dips; 15) sweet and/or savory snacks; 16) chocolates; 17)confectionery sweets; 18) jams and jellies, or the like; and 19) otherspecialty foods and beverages. There may be specific technologicaldifferences between chocolate and coffee processes, due to the distinctnature and properties of the two biomaterials under consideration.

Cocoa liquor (mass), a basic ingredient of chocolate manufacture,contains pre-existing aroma and flavor precursors, developed through thecombination of the cocoa fermentation (carried out at the farm level),which were only partly converted into chocolate volatile andnon-volatile aromas, tastes and flavors during the roasting process.Because the cocoa liquor typically contains around 52% cocoa butter,these formed compounds (e.g., aromas) are properly retained, locked-inand protected within this functional ingredient. In various embodiments,a conching process in chocolate manufacture performs both key andsecondary contribution to the chocolate manufacturing by: 1) strippingresidual water (which otherwise contributes for the increase ofviscosity) of the cocoa/chocolate mass; 2) completing of over 75% offinal aroma and flavor development of the chocolate; and 3) eliminating,through the stripping step, some of the off-flavors associated with thecocoa liquor and other ingredients.

Exemplary differences between chocolate processing technology and ediblecoffee technology (e.g., one or more aspects of the present technology)may exist. For instance, even in the case of non-fermented dried greencoffee beans, the precursors of aroma are already present (in greatamount) in the coffee beans. In various embodiments, when the coffee isroasted, over 90% of the volatile and non-volatile chemicals responsiblefor the coffee aroma and flavor may be formed within the beanconstituents, due to the primary presence of both reactive sugars andamino groups. Under high roasting temperatures employed in one or moreembodiments, the volatile and non-volatile chemicals may undergo adramatic sequence of reactions, known as Maillard reaction ornon-enzymatic browning. In at least one embodiment, the sequence ofreactions culminating with the formation of hundreds of volatiles andnon-volatile compounds may be finalized with the accumulation ofmelanoidins, a powerful antioxidant in roasted coffee. In variousembodiments, induction of further flavor development in coffee, throughsolid-phase reactions may compromise—rather than help the coffee flavorformation and retention.

Moreover, although the coffee flavor volatiles and non-volatilesencompass well over 1,000 compounds, only about 51 chemicals may bedirectly responsible for the coffee aromatic “bouquet” and non-volatilecoffee oil, which is one the main flavor components due to its abilityto carry and retain many coffee volatile aromas. In addition, the about51 chemicals may retain most of the lipo-soluble non-volatile aromasthat contribute to the coffee flavor. In various embodiments, the coffeeoil (e.g., being a PUFA-type oil prone to earlier/easier oxidation)under the traditional roasting process (e.g., high temperatures,relatively long processing time) and under the presence of 02 may beadversely affected by one or more roasting processes, as demonstrated byits relatively short shelf-life. In at least one embodiment, the adverseeffects may be conferred to a finished product (roast and groundcoffee), to which the coffee oil is an important component (which can beapproximately 14-17% of the total). To avoid such adverse effects, thepresent technology may ensure (e.g., from the very beginning of theprocess) the use of effective protective measures for the coffee oilsuch as roasting in the absence of 02. Additional protective measurespresented by the present technology may further include, but are notlimited to, division of present processing technology into two streams,wherein the most impactful thermo-mechanical aspects of the presentprocessing technology are reserved to a non-coffee fraction of thecoffee formulation. In various embodiments, the two streams may be: 1) acoffee processing phase, resulting in a first fraction (referred to asfraction #1); and 2) a non-coffee processing phase, resulting in asecond fraction (referred to as fraction #2).

In one or more embodiments, combination, or lack thereof, of fraction #1and fraction #2 (e.g., in variable proportions) may define one or morecharacteristics of a finished product as well as applications of thefinished product (e.g., if simple or composite coffee mass). In at leastone embodiment, any of the fractions and combination of the twofractions in various proportions may be formed and/or transformed into acommercial finished product that may present one or more featuresincluding, but not limited to: 1) being made with one or more entirecoffee bean, one or more types of coffee beans, or coffee beans from oneor more origins or sources; and 2) being protected against oxidation forover 1 year without addition of any additive and/or, in certainapplications, without need of refrigeration for maintaining itsphysicochemical and organoleptic integrity.

In particular embodiments, in the first stream, coffee (or anotherbiomaterial) may be converted into a coffee liquor and/or coffee liquormass via special cryogenic milling and other processing steps describedherein. In certain embodiments, coffee liquor may be stored as afunctional ingredient and may be prepared for blending with othermaterials and ingredients. In some embodiments, blending processes forblending coffee liquor with other materials and ingredients may beperformed in a time period up to about 2 hours. According to oneembodiment, blending the coffee liquor with the other materials andingredients may be performed in a time period of 10 minutes, 30 minutes,1 hour, or other time periods suitable for homogenously blending thecoffee liquor with the other materials and ingredients.

In various embodiments, the system includes one or more secondaryprocessing stream running in parallel to or concurrently with the firststream, which may include non-coffee ingredients for making a coffeeliquor product, molded, or otherwise. For example, a secondary streammay process ingredients such as sugars, dairy derivatives, complementaryfat systems, bulk ingredients (e.g., maltodextrins, starches), etc. Inat least one embodiment, a secondary stream may utilize a modifiedconching process, which initially eliminates/minimizes off-flavors fromselected ingredients, dramatically reduces residual moisture, induceschanges in the rheology of the mass, and promotes flavor and colorreactions, such as the Maillard reactions through solid-phase reaction.

In certain embodiments, the processing time for loading, dry conching,(partial) wet conching, (partial) homogenization, and wet milling(through recirculation), may be up to about 6-8 hours. According to oneembodiment, the processing time may be between about 10-300 minutes. Invarious embodiments, processing time may depend on one or more factors,such as, for example, the initial quality of distinct biomaterials orthe initial quality of distinct ingredients other than biomaterials.

In at least one embodiment, in response to completing processing of oneor more secondary streams, the first stream material may be processed ina conche and blended with output material from the one or more secondarystream (e.g., to complete homogenization) to form a homogenous coffeeliquor (or other biomaterial) product. In various embodiments, thecoffee liquor product may then be prepared for tempering, molding, andpackaging.

According to various aspects of the present disclosure, the exemplarymulti-stream process may reduce the overall industrial cost, reduce theindustrial processing time (typically from up to 13 hours, to less than5 hours), increase product uniformity of the finished product (e.g.,coffee mass homogeneity in particle size and target viscosity), andreduce overall fat percentage levels of the finished coffee product.

In various embodiments, coffee beans of different origins and/ordifferent levels of roasting may be processed in multiple streams andcombined to create balanced, full-bodied coffee liquor products. In someembodiments, inclusion of more than one type and roast level of coffeemay affect the rheology of the coffee during wet milling processesdescribed herein.

As will be understood, the cellulosic and hemi-cellulosic composition ofthe coffee beans may behave as a plastic and absorb the impact of themill, thereby prolonging milling time to mill the coffee to apredetermined size (e.g., about 20 microns). While the coffee is milled,non-coffee biomaterials present in the recipe may be over-milled, downto about 6-8 microns. In at least one embodiment, the non-coffee orcoffee materials may include sufficient fats to lubricate the particles.

In various embodiments, the present disclosure provides systems andmethods for timely and efficient milling of coffee to small particlesizes (e.g., less than 20 microns). In at least one embodiment, thepresent systems and methods can achieve coffee (and other biomaterial)milling in less time as compared to the time required by previousapproaches, because the present systems and methods allow for coffeeparticles to transition from a plastic state to a glassy state, thusallowing the breakage (by impact) of plastic-like particles when thecoffee particles are re-conditioned to a glassy state.

Modified Conch-Less Processing

In at least one embodiment, the present disclosure provides systems andmethods for processing chocolate or other biomaterials via a distinctsolid-phase reaction process (rather than previous approaches thatperform conventional conching techniques). According to various aspectsof the present disclosure, wet milling (through recirculation) can occurfollowing completion of a homogenization/plasticization stage (e.g., andnot before a dry conching, as per exemplary Swiss method(s)). In variousembodiments, substitution of previous conching techniques may beachieved by implementing unit operations via equipment including, butnot limited to: 1) a blender; 2) a two-stage fluid bed dryer-cooler; 3)a twin screw extruder; 4) cryogenic mill; 5) a ribbon mixer; and 6)combined steam stripping with fractionated distillation column (equippedwith cryogenic condensers).

In various embodiments, the first unit operation can include loading thebiomaterial (except free fat, lecithin, flavoring agents, and additives)into a closed-loop blender (sigma, ribbon or conical screw-type mixer),operating under inert gas atmosphere and blended until reaching ahomogeneous mixture.

In at least one embodiment, the homogenous mixture may be dried (e.g.,to below about 1.5% residual moisture) and/or cooled via a two-stagefluid bed dryer-cooler. In various embodiments, the two-stage fluid beddryer-cooler may operate in a closed-loop and may utilize inert gas(es)to prevent any contact of the homogenous mixture with atmospheric oxygen(at both the drying and the cooling phases of the process).

In one or more embodiments, the dried and cooled homogenous mixture(which may have a residual moisture of less than about 1.5%) may beloaded into a feed hopper that feeds an extruder. In at least oneembodiment, the feed hopper may include an auger feeder with afeed-throat to control the flow through the hopper. In variousembodiments, the feed hopper may receive and deliver the homogenousmixture under inert gas conditions and in complete absence ofatmospheric oxygen.

In at least one embodiment, the extruder may cause transformation of thehomogenous mixture into a homogenous non-coffee fraction by causingefficient solid-phase reactions. In one or more embodiments, theextruder may increase the flavor formation reactions, due to at leastthe following: 1) low moisture of the homogenous mixture favors theMaillard reaction (and other sequential reactions), thereby facilitatingimmediate reaction that transitions the homogenous mixture into thenon-coffee fraction; 2) the combination of high-process shearing,impacting, friction, and temperature within the extruder facilitates ahigher intensity degree of the Maillard reaction; 3) the low-fat contentof a pre-mix provides efficient reactive surface for the solid particlesto increase solid-phase reactions due to precise processing conditionswithin the extruder, thereby accelerating conching effect processes(e.g., from about 5-6 hours to less than about 10-30 minutes); and 4)process parameter optimization allows for obtaining high throughputs ofnon-coffee fraction formulations.

In at least one embodiment, the extruder may include an intermeshingtwin-screw configuration. In various embodiments, the extruder may beassembled in a structure including a heavy bed plate where six heavysteel supporting columns may be attached to the extruder (e.g., fourcolumns for supporting a main barrel, and two columns supporting theremaining elements of the extruder). In at least one embodiment, theextruder may include, but is not limited to, a screwdriver motorequipped with a frequency inverter, reducing gearbox and hopper feeder.

In various embodiments, a central panel may be equipped with a pluralityof elements for controlling the extruder, the plurality of elementsincluding, but not limited to: motor switches, band heater controllers,thermostat, thermistor and/or thermocouple control switches, cryogenicgas expansion valves for a cooling system, barrel (PID) temperaturegauges, heating and cooling elements controls, controls for opening andclosing of the twin screw main body (e.g., the twin barrel or a stator),pressure gauges for reaction areas of the main barrel, controls for ascrews feeder, the armored revolving screw changer, screws rotatinginput/output, metering pumps dosing, feed rate input/output, screwstorque, die temperature, rotary knife (cutting system) rotation, safetycontrols, and other controls for the system.

In a particular embodiment, the barrel may be jacketed and equipped withefficient systems for both cooling and heating (per each section of thetwin screws along the processing extruder barrel), with precisetemperature controls, from 1 to 90 degrees Celsius (or about a meltingpoint of one or more coffee mass ingredients described herein) orhigher, at pressures ranging from 1 to 5 Bar. In at least oneembodiment, the system may also include removable liners for the barrelcovers, pressure gauges and sensors in the key transition (processing)areas of the barrel, two other insertion areas where ingredients can beadded directly in the barrels (respectively for eventual addition ofvarious/special reactants and for heat-sensitive additives).

In at least one embodiment, the twin-screws may be specially designed,where the screws may be designed or modified to include fabricationchanges to: 1) the screws root; 2) the channel width; 3) the flight; 4)the axial flight width; 5) the helix angles; 6) the pitches (variable);7) the screw clearance; 8) the barrel length; 9) the barrel diameter;and 10) special twin-screw designs for providing precise andcontrollable reaction rates, time-temperature and reaction times.

In at least one embodiment, the edge of the twin-screw barrel mayinclude a vacuum degassing port system for degassing and volatilization,integrated with the breaker plate, where there is an extrusion head, apipe die, a screen pack, and a rotary knife cutting system, from whichthe extruder product exits in a closed loop chamber with a stream ofinert gas that mixes with the exhausting gas, and is directly coupled toa fractionation column for off-flavors vent and volatile (cryogenic)recovery.

According to various aspects of the present disclosure, for selectedspecial roasted products, the equipment may also be additionallyequipped with a secondary vacuum sizing system, which may be coupled tothe outlet of the main extruder, which allows for the process to operateunder vacuum, controlled reaction (e.g., cooled with circulation ofcooled refrigerant gas), thus further facilitating the control of theend-process reaction.

In at least one embodiment, the product from the twin-screw extruder maybe subsequently (e.g., immediately) cooled through direct contact withthe cryogenic (inert) gas, through means of a spray placed inside thescrew conveyor that feeds the mill from the top.

In various embodiments, the product may be processed when itstemperature reaches about −80 degrees Celsius, so that the biomaterialis completely in a brittle form.

In a particular embodiment, the process may implement stainless steelmilling balls of various diameters, for example diameters of 0.5 and 0.7mm, milling at a speed of 250 rpm.

According to various aspects of the present disclosure, the process maymill particles to lower than 20 microns in around 20 minutes (underindustrial scale conditions).

In certain embodiments, the extruded product may be a type of chocolatein flavor and taste, and furthermore in a somewhat irregular solid form(depending on the die utilized in the process). In particularembodiments, for using the product as chocolate, the product may bemixed with cocoa butter and/or other suitable fat/oil systemcombinations, according to its planned end use. The finished product maybe versatile for use in food and beverage applications, such as in (butnot limited to): formulation of chocolate bars, chocolate powders,chocolate spreads, and a variety of applications in refrigerated orfrozen desserts, sugar and/or chocolate baked and fried goods, breakfastcereals, power bars, etc.

In at least one embodiment, the ribbon mixer equipment may include adouble helicoid rotating shaft with ancillary paddles and stator devicesto facilitate the creation of turbulence during the mixing operation. Invarious embodiments, the mixer may be designed to operate in closed-loopand under a suitable inert gas. Depending on the end use of the product,the processing temperature may range between 1-70 degrees Celsius viaheated and/or cooled equipment walls. In some embodiments, the mixer mayexhibit variable rotation ranging from 10 to 100 rpm.

In various embodiments, the ribbon mixer may be equipped with anefficient fat/oil spraying system, to facilitate uniform incorporationinto the mass. Other ingredients and additives may be employed at thisstage, such as lecithin, polyglycerol polyricinoleate (“PGPR”), andvarious other food-grade additives. The equipment may exhibit sanitarydesign and may be easy to clean and sanitize. Processing times may bevariable; however, they may typically be between 5 min to 1 hour. Theequipment may be assembled in a platform to facilitate the discharge toinert gas locked-in totes, silos, or directly to the feeding silos ofthe packaging line.

In at least one embodiment, the system may combine an initial steamstripping operation (e.g., injection of 1-15% of water vapor, and/or SHSe.g., super-heated steam), to eliminate the initial off-flavors throughthe distillation column venting. In some embodiments, the systemtemperatures may reach about 65° C. According to various aspects of thepresent disclosure, extraction and cryogenic condensation of thevolatile organic compounds (“VOCs”) may be achieved through a controlledinjection of any suitable inert gas (through the fractionation column).Within the fractionation column, the stream of gases (volatiles) maypass through successive trays (typically 3 to 5 trays), which may bedifferentiated through inner circulation of cryogenic liquids or gasesat various pressures and/or temperatures. In various embodiments, thevolatile gases (e.g., flavor compounds) may be finally recovered ascondensates (from the collection streams of the trays) of these streams,under cryogenic conditions, and the recovered flavor fractions may beadded back to the main processed mass. According to various aspects ofthe present disclosure, the process may be semi-continuous and mayoperate in synchronization with the previous blending stage(s).

Exemplary Agri-Industrial Processing Steps

In at least one embodiment, the systems and methods herein may include(cocoa is exemplary, any biomaterial may be used as appropriate): a)cocoa harvesting; b) cocoa beans fermentation; c) cocoa beans drying,bagging and storage; d) cocoa beans industrial intake; e) cocoa beansdry cleaning; f) cocoa beans wet cleaning; g) cocoa bean drying; h)cocoa bean roasting in absence of oxygen; i) cocoa bean dehulling; j)cocoa nibs cryogenic pre-milling (coarse); k) fat extraction fromcrushed cocoa nibs through SCFE; and l) conch-less processing asdescribed above, implementing unit operations via equipment including,but not limited to: 1) a blender; 2) a two-stage fluid bed dryer-cooler;3) a twin screw extruder; 4) cryogenic mill; 5) a ribbon mixer; and 6)combined steam stripping with fractionated distillation column (equippedwith cryogenic condensers)).

According to various aspects of the present disclosure, the wet milling(through recirculation) may be carried out at the end of thehomogenization/plasticization stage (and not before dry conching, as pertraditional methods). An exemplary process for manufacturing instantpowdered cocoa (and other products) includes: a) cocoa harvesting; b)cocoa beans fermentation; c) cocoa beans drying, bagging and storage; d)cocoa beans industrial intake; e) cocoa beans dry cleaning; f) cocoabeans wet cleaning; g) cocoa bean drying; h) cocoa bean roasting inabsence of oxygen; i) cocoa bean dehulling; j) cocoa nibs cryogenicpre-milling (coarse); k) fat extraction from crushed cocoa nibs throughSCFE; and l) conch-less processing as described above, implementing unitoperations via equipment including, but not limited to: 1) a blender; 2)a two-stage fluid bed dryer-cooler; 3) a twin screw extruder; 4)cryogenic mill; and 5) a ribbon mixer (omitting the combined steamstripping with fractionated distillation column (equipped with cryogeniccondensers)); m) fluid bed agglomeration/instantization/cooling, underclosed-loop, inert gas system; and n) instant cocoa or chocolate powderpackaging.

Exemplary Processing with Alternative Oils

In various embodiments, oils from various biomaterials such as avocados,almonds, and hazelnuts, may be added to processed (or pre-processed)coffee (e.g., coffee processed as discussed herein). In particularembodiments, the oils may be derived from fruits or nuts, and the oilsmay be refined, bleached, and deodorized (RBD) to avoid the introductionof additional off-flavors. In a particular embodiment, processing theoils and coffee may include pre-selecting the roasted beans to bemilled, thus eliminating the substandard particles and beans, and theprocess may be based on ultra-milled coffee liquor under cryogenicconditions, allowing for optimal use of the product in food andbeverages.

In at least one embodiment, the above coffee-oil preparations may beused in the following exemplary ways: 1) sold as a brewed coffee‘gourmet’ enhancer, ready to use (e.g., as concentrated liquid) andreadily soluble/dispersible; 2) used in commercial preparation ofbeverages, such as ready-to-drink (RTD) beverages, hot coffee, hotchocolate, or hot tea beverages—primarily in the form of coffee enhancerand dairy cream, both as non-dairy and dairy cream substitute; 3) incoffee liquor (e.g., 20-40% (coffee enhancer only) and special additives(oils) or with butter oil (coffee dairy cream) and special additives(oils)); and 4) adapted to be suitable also as for cold brew (serving)option. Exemplary equipment and steps for manufacturing the above mayinclude one or more of: a) a line to prepare coffee liquor (from roastedcoffee); b) cryogenic milling equipment; c) a package line (e.g.,product to be packaged in pails or individual units); d) a line forfilling out in cream-type individual or jar type dosing pet packageswith removable aluminum seal.

Exemplary Alternative Coffee Liquor Manufacturing Processes

In an alternative embodiment, the systems and methods herein includealternative processing for coffee liquor via the following steps: a)reception and storage of the ingredients (oils, fats, green coffeebeans); b) green coffee beans dry and wet cleaning/drying and storage;c) green coffee beans roasting under inert atmosphere; d) roasted coffeedry-milling (e.g., to 50-120 microns) under inert atmosphere; e) meltingand storage of the fats and/or oils (under inert gas); f) weighing antransfer of ingredients to a ribbon or sigma mixer (operating underinert gas conditions); g) mixing (e.g., for 1-30 min)/addition ofoptional (other) ingredients; h) under cryogenic conditions, wet milling(using a horizontal or vertical cryogenic ball mill) the coffee mass to10-40 microns to, in part, prevent oxidation of the mass at hightemperature; i) conching under inert gas conditions; j) blending withother conched, refined ingredients; k) tempering; 1) molding or optionalchips dosing; m) cooling tunnel pre-crystallization; n) productun-molding; o) primary and secondary packaging; p) storage andpost-crystallization; and q) shipment.

In some embodiments, the above alternative processes may be used for: i)creating products used as a solid coffee mass, in the form of bars,chips, morsels, chunks, etc.; ii) creating products utilized alone or asa functional ingredient in commercial preparation of hot or coldcoffee—primarily as a black coffee enhancer, or in food applications,when combined with baked or fried goods, ice creams, cookies andcrackers, frozen or refrigerated desserts, pies and tarts, etc.; iii)creating coffee mass with 5-40% (as black coffee enhancer only) (ifcombined with special additives); iv) creating coffee mass with 40-95%(as coffee dairy cream), if combined with butter oil and specialadditives); v) creating instant liquid formulas (ready-to-drink-type(RTD)) could be adapted to be suitable also as hot or cold coffee(serving) option. In at least one embodiment, a coffee enhancerformulation can include, in addition to coffee composite mass and/orother coffee-based ingredients described herein, about 7% by weightcocoa powder and 4% cocoa liquor, and other ingredients describedherein.

In at least one embodiment, exemplary equipment for carrying out theabove exemplary alternative processes includes: A) a line to preparecoffee mass (from green coffee); B) cryogenic milling equipment; C)direct dosing and/or moulding and tempering line; D) a secondary packageline. As will be understood from discussions herein, coffee liquor insolid form may be shipped to a co-packer for filling out in cream-typeindividual or jar type dosing pet packages with removable aluminum seal.

In one or more embodiments, if formulated with other ingredients, theproduct may be shipped as a business-to-business arrangement, whereother food and beverage lines of products may utilize the product as afunctional ingredient to their products.

Exemplary Aroma Capture and Controlled Release

In various embodiments, aromas from the biomaterials (e.g., roastedcoffee) may be captured and implemented for fragrance purposes. Inparticular embodiments, the coffee aromas may be captured via cosmeticpreparation techniques to create a perfume (or similar compound)including various chemical functional groups such as (but not limitedto): aldehydes, esters, alcohols, ketones, lactone, ethers, nitriles,etc. According to various embodiments, the biomaterials may be blendedwith various natural and/or synthetic materials for creating a stableand controllable fragrance compound. In certain embodiments, to increasethe efficacy of any fragrance or flavoring, controlled release of thevolatiles in implemented. In at least one embodiment, active volatilesmay be released to the atmosphere at a desired place, time, and rate.This may be influenced by heat, temperature, pH-sensitive ingredients,etc.

In particular embodiments, the controlled release of the volatiles maybe: 1) delayed; 2) sustained (prolonged); and/or 3) burst released.According to various aspects of the present disclosure, controlledrelease of volatiles may be achieved viaencapsulation/microencapsulation, coacervation, co-crystallization,molecular inclusion, adsorption, etc. Accordingly, the controlledrelease mechanisms involve diffusion-controlled release,osmotic-controlled release, swelling-controlling release, solventactivated controlled release, or moisture-triggered controlled release,among others. In various embodiments, the controlled release of thearomas may be initiated by pressure, melting, pH changes, or changes intemperature, among others.

According to various aspects of the present disclosure, these activevolatiles may be captured and stored within a material such as a rigidor flexible pad, natural and/or artificial flavoring (e.g., in solid,liquid, or gas form). In particular embodiments, these pads, flavors, orother materials may be included within the layers of particularpackaging (e.g., within composite packaging laminates). In at least oneembodiment, the packaging may include bags, boxes, or other forms ofsecondary and/or tertiary packages, and the packaging materials may beporous or semi-permeable to allow for the active volatiles to releasethrough the packaging layers. In some embodiments, the active volatilesmay be included on the exterior of the packaging, or the activevolatiles may be included in a location proximate to one or more unitsof packaging to provide an area with the aroma. As such, the aromaprovided by the active volatiles may influence human behavior (e.g., aconsumer may purchase coffee beans in response to smelling the aromaprovided by the active volatiles).

Process for Reduced Residual Moisture

Because of required application of both quenching and cooling unitoperations (respectively to interrupt the thermolysis, followed by itsstabilization), roasted coffee beans may contain up to 5% of entrappedmoisture. This may present a limitation for the utilization of thisfunctional ingredient in the formulation of products, molded orotherwise. In various embodiments, any residual moisture in the finishedproduct beyond a predetermined residual threshold (e.g., about 1.25-5%)may be capable of significantly increasing the viscosity of the coffeemass, thus creating a hurdle for the moulding process, due todifficulties for proper dosing and filling the coffee mass into themoulds.

Discussed below is an alternative process for eliminating the residualmoisture of roasted coffee beans without affecting the quality andintensity of the coffee aroma. In various embodiments, aspects of thepresent disclosure may allow for finished coffee products of lowerviscosity and full natural coffee flavor, compared to what already maybe true for some chocolate products.

In at least one embodiment, the process may include the followingsteps: 1) roasting coffee beans in the absence of oxygen; 2) dry millingof the coffee into a convenient particle size while in absence ofoxygen, and under controlled low temperature, preferable under cryogenicconditions; 3) freeze-drying the roasted ground coffee under cryogenicconditions from 1 to 36 hours of total processing time, during which thecoffee particles may be progressively heated in order to facilitate thesublimation of water. In some embodiments, the above process may bebatch or continuous. In at least one embodiment, the process iscontinuous, and the freeze-drying chamber may be connected to acryogenic condenser to recover the aromas in water, which would befollowed by an aroma recovery column equipped with a secondary cryogeniccondenser. According to a particular embodiment, the concentrated coffeearoma may then be added back at the end of the production process. Infurther embodiments, coffee (which may be dehydrated) may follow thecoffee liquor production processes discussed herein until the liquor isready and stored, and thus waiting to be proportionally blended with theconched-less coffee and refined product, so that the coffee mass isready for tempering, dosing, moulding, demoulding, and packaged asfinished product.

Quality Control Considerations

In various embodiments, one or more quality requirements of the presentsystems, methods, processes and products may be distinct (e.g., relativeto one or more industry standards). For instance, other industrycommercial grades of green coffee, a certain maximum number and types ofdefects are accepted, as it is assumed that these defects would notinterfere in the overall brewed quality of the prepared coffee cups.Other industry brewing processes use a filter, and, thus, present a lowextraction yield of the operation (typically around 20%). Other industrybrewing processes present a residual moisture of the commercial brewedcoffee as high as 5% due to the alleged need of industrial quenchingpracticed at the end of the roasting operation.

In various embodiments, systems and methods herein roast coffee (andrelated beverage materials) in absence of oxygen and quench roastedcoffee (and other biomaterials at a lower level of residual moisture, toprevent staling (quenching may be feasible even if the residual moistureof the roasted coffee is as low as 1.14%). Thus, in various embodiments,the above-referred (and other) practices may be incompatible with thestandards of quality envisaged for the novel edible coffee product andcorresponding processing technology. Hence, as an entire bean may beutilized in the present systems, methods, and processes, the presence ofdefects in beans (e.g., immature, black, insect-perforated, fermented,etc.) is much less tolerated because the beans may be submitted toultrafine-milling, wherein such defects may be highly amplified, due tothe dramatic increase in surface area of the micro-particles generated.

In one example, to justify this negative amplification effect in thequality of edible coffee, depending on the percentage of defects in thegreen coffee raw material: 1) on average, 1 gram of regular grind coffeefor other industry brewing processes has 1.0 mm particle size, thuscounting around 1,296 particles/g and, therefore, presenting approx. 48sq. Ft. (0.74 sq. m) of surface area; and 2) one gram of an ultra-groundcoffee (defective) with an average of 20 microns (0.02 mm) particlesize, counting around 100,646,912 particles/g, would present approx.2,048 sq. ft. (190.3 sq. m) of surface area—a dramatic 77,660 (x) foldincrease in the number of particles/g, i.e., with the negative potentialimpact to the resulting flavor of the edible coffee product, of courseproportional to the percentage of the defects initially present in theraw material.

Thus, the present methods, systems and processes may call for the almostcomplete removal of the green coffee defects (e.g., to avoid propagationof defects such as described above). The present equipment, methods,systems and processes may be non-conventional, because one or morepresent equipment, methods, systems and processes may never beenutilized (e.g., in other industry practices) in post-cleaning ofcommercial graded green coffees, due to the motives previously informed.In various embodiments, the present technology may be specificallydesigned to encompass two levels of cleaning (e.g., dry and wet), which,previously, may not be utilized in the coffee industry.

Exemplary Method for Further Extending Product Shelf Life

As will be understood from discussion herein, traditional roasting andmilling of green coffee (and other biomaterials) can create staling ofcoffee aroma and taste (e.g., flavor). In addition, green coffee mayslowly oxidize over a period of time (e.g., 6 months) dependent upon: 1)residual moisture (may become critical around 12% and higher); 2)temperature (may become critical around 30 degrees Celsius and higher);3) relative humidity (may become critical around 55% and higher); 4)storage conditions (e.g., ideal conditions include clean and freshventilation); and 5) the presence of commercial impurities (exasperateeffects of which may be exasperated during milling).

In addition, roasting coffee (and other biomaterials) can decrease aromaand taste, along with shelf life. The following may contribute to thedegradation of aroma, taste and shelf life: a) direct or indirect heatsystem; b) roasting in atmosphere, which is deleterious for staling; c)quenching, where either the roasted hot coffee is spread with water, orsimply dumped in an external rotary screen to cool down the roastedbeans using blowing air (such quenching may accelerate an oxidationprocess due to high temperature); d) roasting processes may generate arelatively large amount (e.g., up to 5%) of pyrolysis gases, and entrappyrolysis gases in coffee bean tissue (e.g., about 1-2% may remain inthe coffee after up to 75 days storage). The pyrolysis gases may includeabout 87% carbon dioxide, 7.3% carbon monoxide, 5.3% nitrogen andapproximately 0.4% volatile organic compounds, although other ratios canbe used. In various embodiments, the consequence of the above is thatroasted coffee (and other biomaterials) has a shelf life of a few weeks.

Milling may further accelerate staling and reduce product shelf life dueto the following: i) a high volume of air during milling; ii) mechanicalmilling generates additional heat that may at partially flash-outcertain volatiles, weakening aroma; and iii) expulsion of entrappedpyrolysis gases, rapidly reducing them from about 40-73% of the originalcontent (once the pyrolysis gasses are removed, atmospheric oxygen maydirectly interact with coffee particles).

In addition to the processes described herein, shelf-life may beincreased by blending, under inert gas conditions, a stoichiometricbalanced quality of the following: calcium oxide or calcium hydroxide;magnesium oxide or magnesium hydroxide; sodium oxide or sodiumhydroxide; and/or potassium oxide or potassium hydroxide.

In at least one embodiment, once the material (e.g., roast coffee) isblended with one or more of minerals above, the system may thencryogenically mill the roasted, blended material in the presence of oneor more fats to encapsulate the roasted, blended material. In variousembodiments, the resulting powdered product is protected from oxidationuntil the moment it is placed in contact with hot (or cold) water. Insome embodiments, a stoichiometric reaction takes place, and, dependingon the chemical/mineral additives present, there will be formation ofthe corresponding salts (e.g., carbon dioxide and calcium oxide formcalcium carbonate; carbon dioxide and magnesium oxide form magnesiumcarbonate; carbon dioxide and sodium oxide form sodium carbonate; carbondioxide and potassium oxide form potassium carbonate). As will beunderstood, the above salts are water-soluble and food-grade inparticular quantities.

According to particular embodiments, a modified proposed processincludes: 1) utilizing green coffees of superior grade only, e.g., withfew visible defects; 2) cleaning, (dry and wet), followed by dehydrationunder inert gas; 3) roasting in absence of oxygen; 4) blending theroasted coffee with minerals discussed above (or others) understoichiometric conditions; 5) conduct wet milling under cryogenicconditions; 6) adding 1-15% of specialty oils and fats to millingprocess once particle size is less than or equal to 40 microns (neutraloils or fats, such as refined, bleached, and deodorized oils/fats); 7)further cryogenic milling (e.g., to less than 0.1 to 2 microns); addingany additional ingredients, such as lecithin, salts, aromas,emulsifiers, antioxidants, stabilizers, etc., depending on specificapplication.

Exemplary Soft Inclusion

Various formulations of processed biomaterial may be suitable for use infrozen and refrigerated products, including desserts. It may beadvantageous to provide chips or chunks of biomaterials, such as coffee,for inclusion in frozen or refrigerated food applications by creating asolid chip, chunk, or morsel of edible coffee (or other biomaterial)that is soft at 18-22 degrees Celsius (controlled ambient temperature),but would need to be solid at ice cream storage conditions (−22-−40degrees Celsius). Also, the chips or chunks need to be soft enough thata consumer can consume them (cold, e.g., in ice cream), with a low riskthat the consumer would find the chips/chunks difficult to chew.

The present systems and methods, in some embodiments, overcome the abovetechnical challenges by creating a eutectic depression. In oneembodiment, the system combines recognized incompatible fats to compoundinto a two, three, or multiple fat/oil phase system, that is tailoredfor desirable melting (or fusion). In at least one embodiment, thecharacteristics of the product become relatively soft while theice-cream is consumed (at the mouth temperature), and its correspondingcooling effect while this consumption is progressed. In someembodiments, the system combines types of fat/oil system(s) in such afaction to create purposeful eutectic depression by distorting both thesolid crystallization and crystal melting curves such that the meltingcharacteristics of the resulting product are solid at the ambienttemperature and soft at low temperature.

In at least one embodiment, the soft inclusion formula includes: 1)cocoa butter (or a substitute or equivalent thereof) as a main fatingredient in a at least binary phase system; and 2) at least onecocoa-incompatible fat as a percentage of the cocoa butter (e.g., butteroil), or a CBS fat system in a proportion of the formula total fat phasesystem (e.g., in a tertiary system). As will be understood, theproportions of fats may be defined by: conducting differential scanningcalorimetry (DSC) analyses; analyzing heat flow graphics (e.g.,corresponding to the melting curves and crystallization curves of thefat systems into consideration); analyzing the latent heat of crystalmelting and the latent heat of crystallization, which indicates thedepression points (of the melting and crystallization of the system).

In various embodiments, the system may include adding a viscous liquid(e.g., the processes biomaterial designed and produced as discussedherein) to an ice-cream mass (generally added at the fruit dosing unitand located at the processing phase immediately before the overrunmachine). In some embodiments, the viscous liquid, in contact with theice-cream mass will immediately solidify. As will be understood, therotation shaft of the fruit dosing unit will define the size of theparticles (where lower rotation implies bigger flakes).

The above approach is generally disfavored in the chocolate industry, atleast partially due to inclusion of lauric fatty or other incompatiblefats (e.g. milk fat in white or milk chocolates; or cocoa buttersubstitutes (CBS), in dark chocolates). Moreover, the chocolate industryavoids combining cocoa butter with any type of CBS and/or fats or oilscapable of generating a eutectic depression during fusion orcrystallization curves within what is considered the adequatetemperature zone for the processing technology of solid chocolates.

Exemplary Coating

According to various aspects, the systems and methods may include addinga coating to the biomaterials discussed herein, which may extend shelflife of various products. The coating process is carried out usingselected processed materials that presents physical, chemical &sensorial characteristics of edible films. This way, while they presenta physical barrier to atmospheric oxygen, they extent the shelf-life ofthe roasted coffee (before it is milled), allowing for prolonged storageunder normal packaging conditions.

It some embodiments, the systems and methods include: 1) roastingcleaned green coffee in the absence of oxygen; 2) coating each roastedcoffee bean inside an apparatus (typically an especial fluid bed drierand cooler) operating under absence of oxygen; 3) sealing the roasted,coated coffee beans in the absence of oxygen until further processing;4) milling the roasted, coated coffee beans. In various embodiments, thecoating is a suitable combination of proteins, oils, fats, extracts,carbohydrates, cellulose (and its derivatives), and starch (and itsderivatives) and is (one or more of): a) 100% food grade; b)biodegradable; c) impermeable to coffee volatiles release; d)preventative of microbial penetration or growth; e) able to maintainfilm integrity under reasonable cold or hot storage conditions; f)preventative of water loss or absorption; g) hydro-soluble and/orlipo-soluble; h) calories free or low calorie; i) preventative of oxygenpenetration; j) of a high elongated film tensile strength; k)mechanically resistive to friction wear; and l) absent flavor (i.e.,neutral) or is of a suitable flavor.

According to particular embodiments, the system may include one or morefluid bed microencapsulation or coating systems and processes, which mayimprove dispersibility and increase protection against oxygen whileadding-back of natural fats and/or oils and other biomaterials, topotentially improve natural flavoring. In various embodiments, a powder(e.g., as created from processes discussed herein) may bemicroencapsulated or agglomerated and coated.

In one embodiment, powder is sprayed with food ingredients and/oradditives in a closed- or semi-closed loop fluid bed drier (or cooler),under refrigerated inert gas conditions. In various embodiments, thepowder is sprayed in batch or continuous fluid bed-type equipment via aspray (drier, cooler or freezer), or freeze drier.

In some embodiments, microencapsulating powder by spraying foodingredients and/or additives in a closed or semi-closed loop fluid-beddrier (or cooler) within a refrigerated inert gas environment results incoated powder particles. In one or more embodiments, coffee oil andspecific food or additive microencapsulating solutions and/ordispersions may be simultaneously pulverized through spray nozzlesconfigured to coat the individual powder particles.

According to particular embodiments, powder (ultrafine or otherwise) isagglomerated under refrigerated inert gas conditions, in a closed-loopor semi-closed loop fluid bed (dryer or cooler)-type “agglomerator”(batch or continuous). In various embodiments, the resulting powder(either from the micro-encapsulated step, or from the agglomeratedparticles) may be kept inside a chamber in dried conditions. In at leastone embodiment, storage under dried conditions may prevent themicro-encapsulated ultra-fine milled coffee particles or agglomeratedultrafine powder from adhering to each other, or to the inner wall ofthe fluid bed unit.

In a further embodiment, an exemplary microencapsulation or coatingprocess may include wetting (with cold water), agglomeration, drying,and cooling. In some embodiments, the system continuously micro-sprayssuitable food grade ingredient or additives solution through nozzlesthat are configured to apply film coating to the agglomerated particleswith a total spread content from about 0.5% to 15% weight/weight of apowder (e.g., depending on a desired level of protection and propertiesof the agglomerates).

Conclusion

Additional aspects, features, and methodologies of the claimed systems,methods, formulations, and products will be readily discernible from thedescription herein, by those having ordinary skill in the art. Manyembodiments and adaptations of the disclosure and claimed systems,methods, formulations, and products other than those herein described,as well as many variations, modifications, and equivalent arrangementsand methodologies, will be apparent from or reasonably suggested by thedisclosure and the foregoing description thereof, without departing fromthe substance or scope of the claims. Furthermore, any sequence(s)and/or temporal order of steps of various processes described andclaimed herein are those considered to be the best mode contemplated forcarrying out the claimed systems, methods, formulations, and products.It should also be understood that, although steps of various processesmay be shown and described as being in a preferred sequence or temporalorder, the steps of any such processes are not limited to being carriedout in any particular sequence or order, absent a specific indication ofsuch to achieve a particular intended result. In most cases, the stepsof such processes may be carried out in a variety of different sequencesand orders, while still falling within the scope of the claimed systems,methods, formulations, and products. In addition, some steps may becarried out simultaneously, contemporaneously, or in synchronizationwith other steps.

The embodiments were chosen and described in order to explain theprinciples of the claimed systems, methods, formulations, and productsand their practical application so as to enable others skilled in theart to utilize the systems, methods, formulations, and products andvarious embodiments and with various modifications as are suited to theparticular use contemplated. Alternative embodiments will becomeapparent to those skilled in the art to which the claimed systems,methods, formulations, and products pertain without departing from theirspirit and scope. Accordingly, the scope of the claimed systems,methods, formulations, and products are defined by the appended claimsrather than the foregoing description and the exemplary embodimentsdescribed therein.

Clause 1. A system for producing coffee liquor, comprising: a drycleaning and separating system configured to receive a quantity ofcoffee beans, the dry cleaning and separating system comprising: atwo-sieve separator configured to remove coarse impurities from thequantity of coffee beans; an aspirator channel configured to beconnected to the two-sieve separator and to remove dust, sand, lightbeans, and bean chaffs from the quantity of coffee beans; a separatorconfigured to be connected to the aspirator channel and to remove heavyimpurities, stones, and pebbles from the quantity of coffee beans; ametal separator configured to be connected to the separator and toremove metal contaminants from the quantity of coffee beans; and acluster mechanism configured to be connected to the metal separator andto recover a portion of the quantity of coffee beans, and output asecond quantity of coffee; a wet cleaning and separating systemconfigured to be connected to the dry cleaning and separating system,the wet cleaning and separating system comprising: a continuous beanwasher configured to remove residues from the second quantity of coffeebeans; a wire meshing screen configured to be connected to thecontinuous bean washer and to remove excess water from the secondquantity of coffee beans; a clean bean dryer configured to be connectedto the wire meshing screen and to dry the second quantity of coffeebeans; a bean size sorter configured to be connected to the clean beandryer and to separate out one or more portions of the second quantity ofcoffee beans based on coffee bean size; a bean density sorter configuredto be connected to the bean size sorter and to separate out one or moresecondary portions of the second quantity of coffee beans and the one ormore portions based on coffee bean density; an optical color sorterconfigured to be connected to the bean density sorter and to separateout one or more portions of the second quantity of coffee beans and theone or more secondary portions based on coffee bean color to produce asorted quantity of beans and one or more tertiary portions; apeeler-polisher configured to be connected to the optical color sorterand to polish and peel the sorted quantity of beans to create a quantityof peeled beans and the one or more tertiary portions to create one ormore quaternary portions; and a clean green coffee blender configured tobe connected to the peeler-polisher and to blend the quantity of peeledbeans and the one or more quaternary portions into a quantity of cleanbeans; a drying mechanism configured to be connected to the wet cleaningand separating system and to dry the quantity of clean beans and producea quantity of dry beans; a three-size classification system configuredto be connected to the drying mechanism and to separate the quantity ofdry beans into one or more sized portions based on bean size; a roastingsystem configured to be connected to the three-size classificationsystem and to roast each of the one or more sized portions under inertgas conditions and in the absence of oxygen, wherein the roasting systemcomprises: a bean chamber configured to receive each of the one or moresized portions, wherein the bean chamber is contained within a roastingchamber; the roasting chamber, wherein: the roasting chamber issurrounded by heating media configured to heat the roasting chamber to apredetermined roasting temperature for a predetermined roasting timeperiod, thereby roasting of each of the one or more size portions toproduce roasted coffee; and the roasting chamber is configured to bepressurized with inert gas to a predetermined roasting pressure for thepredetermined time period; a torrefacto system configured to beconnected to the roasting system, the torrefacto system comprising: atwo-stage vibratory fluid bed cooler configured to transport the roastedcoffee under inert gas conditions and in the absence of oxygen; a spraymechanism configured to coat the roasted coffee with a solution duringtransportation by the fluid bed cooler, wherein the solutionencapsulates and substantially prevents oxidation of the roasted coffee;a pre-cooling system configured to be connected to the torrefacto systemand to cool the roasted coffee in the absence of oxygen through directcontact with a refrigerated inert gas to a first cooled temperature fora predetermined cooling time period; a post-cooling system configured tobe connected to the pre-cooling system and to further cool the roastedcoffee in the absence of oxygen and under inert gas conditions to asecond cooled temperature, wherein the roasted coffee is kept at thesecond cooled temperature and ambient pressure for a predetermineddegassing time period while the roasted coffee undergoes degassing; adry mill configured to be connected to the post-cooling system and tomill the roasted coffee beans to a predetermined size under cryogenicand inert conditions and in the absence of oxygen to produce dry milledcoffee; a supercritical fluid extraction (SCFE) system configured to beconnected to the dry mill and to extract fats and coffee oil from thedry milled coffee to produce a coffee product, wherein the SCFE systemcomprises: two or more extraction columns, each extraction columnconfigured to introduce supercritical liquid carbon dioxide to apermeation column; and each permeation column configured to introducethe supercritical liquid carbon dioxide to the dry milled coffee at apredetermined SCFE pressure while the dry milled coffee is kept at apredetermined SCFE temperature, wherein introducing the supercriticalliquid carbon dioxide causes separation and extraction of the fats andcoffee oil from the dry milled coffee and yields the coffee product; awet mill configured to be connected to the SCFE system and to mill thecoffee product to a second predetermined size under inert gas conditionsand in the absence of oxygen to produce coffee powder, wherein the wetmill operates below a predetermined wet mill temperature and the coffeeproduct is kept at a second predetermined wet mill temperature; a firstmixer configured to be connected to the wet mill and to mix the coffeepowder with one or more oils and one or more fats under inert gasconditions and in the absence of oxygen to produce a coffee fraction; asecond mixer configured to be connected to the first mixer and to mixthe coffee fraction with a non-coffee fraction to produce a compositecoffee mass, wherein the second mixer comprises a spray mechanism foradding one or more ingredients to the coffee oil to the composite coffeemass; and a filtration system configured to be connected to the secondmixer, comprising: a positive displacement pump configured to pump thecoffee mass through one or more filter screens; the one or more filterscreens configured to filter selected media from the coffee mass; one ormore cleaning mechanisms attached to each of the one or more filterscreens, wherein each cleaning mechanism comprises a disc configured totravel up and down the filter screen, parallel to the flow of the coffeeproduct to scrape the selected media off the filter screen; and one ormore collection chambers configured to be attached to each of the one ormore filter screens, wherein each collection chamber is configured toreceive the selected media scraped by the one or more cleaningmechanisms and automatically purge the selected media within apredetermined purge period.

Clause 2. The system of clause 1 or any other clause herein, wherein thecleaning and separated system reduces defects in the coffee beans by afactor of about 10×.

Clause 3. The system of clause 1 or any other clause herein, wherein thethree-size classification system comprises: a small screen for capturinga small bean quantity and comprising small apertures, wherein each smallaperture is sized to about 5.5 mm; a medium screen for capturing amedium bean quantity and comprising medium apertures, wherein eachmedium aperture is sized to about 6.5 mm; and a large screen forcapturing a large bean quantity and comprising large apertures sized toabout 8.0 mm.

Clause 4. The system of clause 1 or any other clause herein, wherein thebean chamber comprises one or more rotary cylinders that rotate withinthe roasting chamber.

Clause 5. The system of clause 1 or any other clause herein, wherein thebean chamber is a fluid bed chamber.

Clause 6. The system of clause 1 or any other clause herein, wherein thepredetermined roasting temperature, predetermined roasting time periodand predetermined roasting pressure are based on a low, medium, or highroasting profile.

Clause 7. The system of clause 1 or any other clause herein, wherein:the predetermined roasting temperature is between about 100-230 degreesCelsius; the predetermined roasting time period is between about 2-60minutes; and the predetermined roasting pressure is between about 1-10bar.

Clause 8. The system of clause 1 or any other clause herein, wherein theroasted coffee chaff separation further comprises a mechanism forproviding continuous aspiration through a separation cyclone to returnclean inert gas to the roasting chamber.

Clause 9, The system of clause 1 or any other clause herein, wherein thesolution comprises about 10-60% solids by weight of the solution.

Clause 10. The system of clause 9 or any other clause herein, whereinthe solution comprises sugar.

Clause 11. The system of clause 1 or any other clause herein, whereinthe first cooled temperature is between about 50-100 degrees Celsius.

Clause 12. The system clause of 11 or any other clause herein, whereinthe first cooled temperature is between about 65-75 degrees Celsius.

Clause 13. The system of clause 12 or any other clause herein, whereinthe predetermined cooling time period is about 1 minute.

Clause 14. The system of clause 13 or any other clause herein, wherein:the second cooled temperature is ambient temperature; and thepredetermined degassing time period is about one day.

Clause 15. The system of clause 1 or any other clause herein, whereinthe post cooling system and the degassing system comprise a mechanicalvibratory screen that transports the roasted coffee beans while therefrigerated inert gas contacts and cools the roasted coffee beans.

Clause 16. The system of clause 1 or any other clause herein, whereinthe predetermined size is between about 75-500 microns.

Clause 17. The system of clause 16 or any other clause herein, whereinthe predetermined size is between about 100-300 microns and thepredetermined size is selected to prevent filter plugging.

Clause 18. The system of clause 16 or any other clause herein, whereinthe dry milling occurs at a temperature between about −190 to (+) 10degrees Celsius.

Clause 19. The system of clause 1 or any other clause herein, wherein:the predetermined SCFE temperature is between about 30-90 degreesCelsius; and the predetermined SCFE pressure is about 150 to 450 bars.

Clause 20. The system of clause 19 or any other clause herein, whereinthe supercritical liquid carbon dioxide is introduced to the dry milledcoffee until a portion of oil in the dry milled coffee reaches apredetermined oil threshold.

Clause 21. The system of clause 20 or any other clause herein, whereinthe predetermined oil threshold is about 7% or less oil remaining in thedry milled coffee.

Clause 22. The system of clause 21 or any other clause herein, whereinthe oil and fat are stored individually under cryogenic conditions.

Clause 23. The system of clause 22 or any other clause herein, whereinthe oil and fat are collected and separated through two or more fluidcollectors.

Clause 24. The system of clause 23 or any other clause herein, whereinthe fats are stored in a pumpable condition under inert gas conditionsat 40-45 degrees Celsius.

Clause 25. The system of clause 1 or any other clause herein, wherein:the second predetermined size is between about 0.1-10.0 microns; thepredetermined wet mill temperature is between about −190 to (+) 10degrees Celsius; the second predetermined wet mill temperature isbetween about −80 to (+) 10 degrees Celsius; and the coffee powder iskept under inert gas conditions to prevent aroma deterioration.

Clause 26. The system of clause 25 or any other clause herein, whereinthe second predetermined size is less than about 2 microns.

Clause 27. The system of clause 1 or any other clause herein, whereinthe mixer is a ribbon mixer.

Clause 28. The system of clause 1 or any other clause herein, whereinthe mixer is a sigma mixer.

Clause 29. The system of clause 27 or any other clause herein, wherein:the mixer performs mixing at a speed between about 20-150 rpm; the oneor more oils comprise one or more oils selected from the groupcomprising MCT coconut fraction or other drupe-based oils, fruit-basedoils, seed-based oils, cereal-based oils, butter oil, and ghee; the oneor more fats comprise one or more fats selected from the groupcomprising seed-based fat extracts, cereal-based fat extracts, and ghee;and the one or more oils and the one or more fats comprise between about0.5-15.0% by weight of the coffee powder.

Clause 30. The system of clause 27 or any other clause herein, whereinthe mixer comprises a spray system configured to: coat the coffee powderwith up to 200% by weight of the coffee powder of the one or more oilsand the one or more fats; perform coating in cycles running betweenabout 1-100 minutes, wherein the spray system sprays the one or moreoils and the one or more fats in droplets measuring less than about 100microns.

Clause 31. The system of clause 27 or any other clause herein, whereinthe mixer is further configured to heat the coffee powder to about 90degrees Celsius and the cool the coffee powder to about 10 degreesCelsius.

Clause 32. The system of clause 1 or any other clause herein, wherein:the one or more ingredients are selected from the group comprising thecoffee oil, the fats, aromas, and one or more additives; and the spraymechanism is configured to spray the one or more ingredients in up to200% the mass of the composite coffee mass, in droplets measuring lessthan about 100 microns, in one or more processing cycles each measuring1-100 minutes; the second mixer is further configured to: heat thecomposite coffee mass up to about 90 degrees Celsius and cool thecomposite coffee mass down to about 10 degrees Celsius during aprocessing run measuring between about 5-60 minutes; and mix the coffeefraction and the non-coffee fraction at about 10-100 rpm with a doublehelicoid rotating shaft comprising ancillary paddles and stator devicesto create turbulence during the mixing.

Clause 33. The system of clause 32 or any other clause herein, whereinthe one or more additives comprise one or more additives selected fromthe group comprising salts, lecithin, polyglycerol polyricinoleate,emulsifiers, antioxidants, stabilizers, and other food-grade additives.

Clause 34. The system of clause 33 or any other clause herein, whereinthe second mixer is a ribbon mixer.

Clause 35. The system of clause 34 or any other clause herein, whereinthe second mixer is a sigma mixer.

Clause 36. The system of clause 1 or any other clause herein, whereinthe predetermined purge period is about 0.7 seconds.

Clause 37. A system for dry cleaning and separating coffee beans,comprising: a two-sieve separator configured to remove coarse impuritiesfrom the quantity of coffee beans; an aspirator channel connected to thetwo-sieve separator and configured to remove dust, sand, light beans,and bean chaffs from the quantity of coffee beans; a separator connectedto the aspirator channel and configured to remove heavy impurities,stones, and pebbles from the quantity of coffee beans; a metal separatorconnected to the separator and configured to remove metal contaminantsfrom the quantity of coffee beans; and a cluster mechanism connected tothe metal separator and configured to recover a portion of the quantityof coffee beans, wherein the cluster mechanism outputs a second quantityof coffee.

Clause 38. A process for dry cleaning and separating coffee beans,comprising: removing coarse impurities from a quantity of coffee beansby processing the quantity of coffee beans through a two-sieveseparator; removing dust, sand, light beans, and bean chaffs from thequantity of coffee beans by processing the quantity of coffee beansthrough an aspirator channel; removing heavy impurities, stones, andpebbles from the quantity of coffee beans by processing the quantity ofcoffee beans through one or more separators; removing metal contaminantsfrom the quantity of coffee beans by processing the quantity of coffeebeans through one or more metal separators; and recovering a portion ofcoffee beans removed from the quantity of coffee beans.

Clause 39. A system for wet cleaning and separating coffee beans,comprising: a continuous bean washer configured to remove residues froma quantity of coffee beans; a wire meshing screen connected to thecontinuous bean washer and configured to remove excess water from thequantity of coffee beans; a clean bean dryer connected to the wiremeshing screen and configured to dry the quantity of coffee beans; abean size sorter connected to the clean bean dryer and configured toseparate out one or more portions of the quantity of coffee beans basedon coffee bean size; a bean density sorter connected to the bean sizesorter and configured to separate out one or more secondary portions ofthe quantity of coffee beans and the one or more portions based oncoffee bean density; an optical color sorter connected to the beandensity sorter and configured to separate out one or more portions ofthe quantity of coffee beans and the one or more secondary portionsbased on coffee bean color to produce a sorted quantity of beans and oneor more tertiary portions; a peeler-polisher connected to the opticalcolor sorter and configured to polish and peel the sorted quantity ofbeans to create a quantity of peeled beans and the one or more tertiaryportions to create one or more quaternary portions; and a clean greencoffee blender connected to the peeler-polisher and configured to blendthe quantity of peeled beans and the one or more quaternary portionsinto a quantity of clean beans.

Clause 40. A process for dry cleaning and separating coffee beans,comprising: removing residues from a quantity of coffee beans byprocessing the quantity of coffee beans through a continuous beanwasher; removing excess water from the quantity of coffee beans byprocessing the quantity of beans through a wire meshing screen; dryingthe quantity of beans by processing the quantity of beans through aclean bean dryer; separating one or more portions from the quantity ofcoffee beans based on coffee bean size by processing the quantity ofcoffee beans through a bean size sorter; separating one or moresecondary portions from the quantity of coffee beans based on coffeebean density by processing the quantity of coffee beans through a beandensity sorter; separating one or more tertiary portions from thequantity of coffee beans based on coffee bean color by processing thequantity of coffee beans through an optical color sorter, whereinseparating the one or more tertiary portions yields a quantity of sortedcoffee beans; peeling and polishing the sorted quantity of coffee beansand the one or more tertiary portions by processing sorted quantity ofcoffee beans and the one or more tertiary portions through apeeler-polisher, wherein peeling and polishing the sorted quantity ofbeans yields a quantity of peeled beans, and peeling and polishing theone or more tertiary portions yields one or more quaternary portions;and blending the quantity of peeled beans and the one or more quaternaryportions in a clean green coffee blender, wherein blending yields aquantity of clean beans.

Clause 41. A system for producing a coffee fraction, comprising: aroasting system connected to configured to roast a quantity of beansunder inert gas conditions and in the absence of oxygen, wherein theroasting system comprises: a bean chamber that receives each of thequantity of beans, wherein the bean chamber is contained within aroasting chamber; and the roasting chamber, wherein: the roastingchamber is surrounded by heating media configured to heat the roastingchamber to a predetermined roasting temperature for a predeterminedroasting time period, thereby roasting the quantity of beans to produceroasted coffee; and the roasting chamber is pressurized with inert gasto a predetermined roasting pressure for the predetermined time period;a torrefacto system connected to the roasting system, the torrefactosystem comprising: a two-stage vibratory fluid bed cooler thattransports the roasted coffee under inert gas conditions and in theabsence of oxygen; a spray mechanism that coats the roasted coffee witha solution during transportation by the fluid bed cooler, wherein thesolution encapsulates and substantially prevents oxidation of theroasted coffee; a pre-cooling system connected to the torrefacto systemand configured to cool the roasted coffee in the absence of oxygenthrough direct contact with a refrigerated inert gas to a first cooledtemperature for a predetermined cooling time period; a post-coolingsystem connected to the pre-cooling system and configured to furthercool the roasted coffee in the absence of oxygen and under inert gasconditions to a second cooled temperature, wherein the roasted coffee iskept at the second cooled temperature and ambient pressure for apredetermined degassing time period while the roasted coffee undergoesdegassing; a dry mill connected to the post-cooling system andconfigured to mill the roasted coffee beans to a predetermined sizeunder cryogenic and inert conditions and in the absence of oxygen toproduce dry milled coffee; a supercritical fluid extraction (SCFE)system connected to the dry mill and configured to extract fats andcoffee oil from the dry milled coffee to produce a coffee product,wherein the SCFE system comprises: two or more extraction columns, eachextraction column configured to introduce supercritical liquid carbondioxide to a permeation column; and each permeation column configured tointroduce the supercritical liquid carbon dioxide to the dry milledcoffee at a predetermined SCFE pressure while the dry milled coffee iskept at a predetermined SCFE temperature, wherein introducing thesupercritical liquid carbon dioxide causes separation and extraction ofthe fats and coffee oil from the dry milled coffee and yields the coffeeproduct; a wet mill connected to the SCFE system and configured to millthe coffee product to a second predetermined size under inert gasconditions and in the absence of oxygen to produce coffee powder,wherein the wet mill operates below a predetermined wet mill temperatureand the coffee product is kept at a second predetermined wet milltemperature; and a first mixer connected to the wet mill and configuredto mix the coffee powder with one or more oils and one or more fatsunder inert gas conditions and in the absence of oxygen to produce acoffee fraction.

Clause 42. A process for producing a coffee fraction, comprising:delivering a quantity of coffee beans into a bean chamber containedwithin a roasting chamber: heating the roasting chamber via heatingmedia to a predetermined roasting temperature for a predeterminedroasting time period to roast the quantity of coffee beans and produceroasted coffee; transporting the roasted coffee via a two-stagevibratory fluid bed cooler under inert gas conditions and in the absenceof oxygen; spraying the roasted coffee with a solution via a spraymechanism, wherein the solution encapsulates and substantially preventsoxidation of the roasted coffee; cooling the roasted coffee in theabsence of oxygen to a first cooled temperature for a predeterminedcooling period; cooling the roasted coffee in the absence of oxygen to asecond cooled temperature; degassing the roasted coffee by maintainingthe roasted coffee at the second cooled temperature and at ambientpressure for a predetermined degassing time period; dry milling theroasted coffee to a predetermined size under cryogenic and inert gasconditions and in the absence of oxygen to produce dry milled coffee;extracting fats and coffee oil from the dry milled coffee via asupercritical fluid extraction (SCFE) system to produce coffee product,the SCFE system comprising: two or more extraction columns, eachextraction column configured to introduce supercritical liquid carbondioxide to a permeation column; and each permeation column configured tointroduce the supercritical liquid carbon dioxide to the dry milledcoffee at a predetermined SCFE pressure while the dry milled coffee iskept at a predetermined SCFE temperature, wherein introducing thesupercritical liquid carbon dioxide causes separation and extraction ofthe fats and coffee oil from the dry milled coffee and yields the coffeeproduct; wet milling the coffee product to a second predetermined sizeunder inert gas conditions and in the absence of oxygen to producecoffee powder, wherein the wet milling is performed below apredetermined wet mill temperature while the coffee product is kept at asecond predetermined wet mill temperature; mixing, in a mixer, thecoffee powder with one or more oils and one or more fats under inert gasconditions and in the absence of oxygen to produce a coffee fraction.

Clause 43. A system for producing a composite coffee mass, comprising: amixer configured to mix a coffee fraction and a non-coffee fraction toproduce a composite coffee mass, wherein the mixer comprises a spraymechanism for adding one or more ingredients to the coffee oil to thecomposite coffee mass; and a filtration system connected to the mixer,comprising: a positive displacement pump configured to pump the coffeemass through one or more filter screens; the one or more filter screensconfigured to filter selected media from the coffee mass; one or morecleaning mechanisms attached to each of the one or more filter screens,wherein each cleaning mechanism comprises a disc configured to travel upand down the filter screen, parallel to the flow of the coffee productto scrape the selected media off the filter screen; and one or morecollection chambers attached to each of the one or more filter screens,wherein each collection chamber is configured to receive the selectedmedia scraped by the one or more cleaning mechanisms and automaticallypurge the selected media within a predetermined purge period.

Clause 44. A process for producing a composite coffee mass, comprising:

mixing, in a mixer, a coffee fraction and a non-coffee fraction toproduce a composite coffee mass; spraying, via a spray mechanism, thecomposite coffee mass with one or more ingredients; and pumping, via apositive displacement pump, the composite coffee mass through one ormore filter screens; filtering, via the one or more filter screens,selected media out of the composite coffee mass; scraping the selectedmedia from the one or more filter screens via one or more cleaningmechanisms attached to each filter screen, wherein each cleaningmechanisms comprises a disc configured to travel up and down the filterscreen and scrape the selected media into one or more collectionchambers; and purging the selected media from the one or more collectionperiods within a predetermined purge period.

Clause 45. An edible coffee liquor mass comprising: coffee liquormanufactured under inert conditions and in the absence of oxygen,wherein the coffee liquor comprises: coffee particles milled to aparticle size between about 0.1 to 40 microns and a moisture content ofless than about 1.25%, wherein the coffee particles are milled undercryogenic and inert gas conditions in the absence of oxygen from coffeebeans roasted under inert gas conditions and in the absence of oxygen; asolution encapsulating the coffee particles, wherein: the solutionsubstantially prevents oxidation of the coffee particles; and thesolution comprises up to about 5% by weight of the coffee liquor; one ormore additives selected from the group comprising fats, oils, andaromas, wherein the one or more additives comprise about 1-15% by weightof the coffee liquor; and wherein the edible coffee liquor massdemonstrates a shelf life of at least one year under ambient temperatureand pressure.

Clause 46. A system for producing a non-coffee fraction, comprising: aribbon blender configured to: receive a plurality of ingredients; mixthe plurality of ingredients into a substantially homogenous mixtureunder inert gas conditions and in the absence of oxygen; a two-stagefluid bed dryer-cooler configured to dry and cool the substantiallyhomogenous mixture under inert gas conditions and in the absence ofoxygen, wherein: the fluid bed dryer-cooler dries the substantiallyhomogenous mixture to a moisture level below a predetermined moisturethreshold under inert gas conditions and in the absence of o; and thefluid bed dryer-cooler cools the substantially homogenous mixture to atemperature below a predetermined temperature threshold; an extrudercomprising two or more intermeshing screws configured to shear thesubstantially homogenous mixture under inert gas conditions and in theabsence of oxygen, wherein the shearing causes friction, heat, andpressure that induces a Maillard reaction in the section mixture thatproduces a second mixture; a milling system configured to cool and millthe second mixture under inert gas conditions and in the absence ofoxygen, wherein: the milling system cools the second mixture below asecond predetermined temperature threshold; and the milling system millsthe cooled second mixture at a predetermined speed to a predetermineddiameter for a predetermined time period to create a third mixture; anda ribbon mixer configured to mix the third mixture under inert gasconditions and in the absence of oxygen, wherein the mixer comprises: adouble helicoid rotating shaft for mixing the third mixture at a secondpredetermined speed and within a third predetermined temperaturethreshold, wherein the double helicoid rotating shaft comprisesancillary paddles and stator devices that create turbulence during themixing; and a spraying system configured to spray and encapsulate thethird mixture with one or more fats, oils, and other ingredients topreserve flavor and improve shelf life of the non-coffee fraction; and afractionated distillation column that injects super-heated steam intothe third mixture, wherein: the super-heated steam comprises 1-15% byweight of the third mixture; the super-heated steam removes volatilesfrom the third mixture; and the super-heated steam passes through asuccession of trays differentiated through cryogenic liquids and gassesat a plurality of temperatures and pressures, wherein the succession oftrays cause condensation of the volatiles and the condensed volatilesare collected from the succession of trays under cryogenic conditions.

Clause 47. The system of clause 46 or any other clause herein, whereinthe predetermined moisture threshold is about 1.5%.

Clause 48. The system of clause 46 or any other clause herein, whereinthe extruder further comprises: a screw barrel attached to andsurrounding the two or more intermeshing screws, the screw barrelcomprising a natural vacuum degassing port integrate with a breakerplate; an extrusion head connected to the breaker plate; a pipe dieconnected to the extrusion head; a screen pack connected to the pipedie; and a rotary cutting system connected to the screen pack, whereinthe second mixture exits the extruder via the rotary cutting system.

Clause 49. The system of 48 or any other clause herein, wherein thesecond mixture exits the extruder with a stream of inert gas that mixeswith the exhausting gas and is coupled to a fractionation column foroff-flavor venting and volatile recovery.

Clause 50. The system of 48 or any other clause herein, wherein thescrew barrel further comprises one or more cooling and heatingmechanisms along a length of the each two or more intermeshing screws,each of the one or more cooling and heating mechanisms configured toheat the second mixture to between about 1 to 90 degrees Celsius.

Clause 51. The system of clause 46 or any other clause herein, whereinthe extruder is further configured to apply pressure to thesubstantially homogeneous product between about 1 to 5 Bar.

Clause 52. The system of clause 46 or any other clause herein, whereinthe barrel includes insertion areas for adding ingredients to the secondmixture.

Clause 53. The system of clause 46 or any other clause herein, wherein:the second predetermined temperature threshold is about −80 degreesCelsius; the predetermined speed is about 250 rpm; the predetermineddiameter is less than about 20 microns; and the predetermined timeperiod is about 20 minutes.

Clause 54. The system of 53 or any other clause herein, wherein thesecond predetermined speed is between about 10 to 100 rpm and the thirdpredetermined temperature threshold is between about 1 to 70 degreesCelsius.

Clause 55. The system of clause 46 or any other clause herein, whereinthe moisture level increases a rate of the Maillard reaction.

Clause 56. A coffee enhancer, comprising: a first portion comprisingcoffee liquor produced under the absence of oxygen; and a second portionmixed with the first portion under the absence of oxygen, the secondportion comprising additives.

Clause 57. The coffee enhancer of clause 56 or any other clause herein,wherein the first portion comprises about 5-40% percent by weight of thecoffee enhancer.

Clause 58. The coffee enhancer of clause 56 or any other clause herein,wherein the first portion comprises about 40-95% percent by weight ofthe coffee enhancer.

Clause 59. The coffee enhancer of clause 56 or any other clause herein,wherein the additives comprise butter oil.

Clause 60. The coffee enhancer of 56 or any other clause herein, whereinthe butter oil is cocoa butter oil.

Clause 61. The coffee enhancer of 56 or any other clause herein, whereinthe butter oil is cocoa butter substitute (CBS) oil.

Clause 62. The coffee enhancer of clause 56 or any other clause herein,wherein the coffee enhancer is a solid.

Clause 63. The coffee enhancer of clause 56 or any other clause herein,wherein the coffee enhancer does not require pasteurization, coolstorage, or in-house packaging.

Clause 64 The coffee enhancer of clause 56 or any other clause herein,wherein the first portion and second portion comprise a particle size ofabout 10-30 microns.

Clause 65. A method for producing coffee enhancer, comprising: receivinga first portion comprising coffee liquor produced in the absence ofoxygen; milling the first portion to about 50-120 microns undercryogenic conditions in the absence of oxygen; mixing, in a mixer and inthe absence of oxygen, the first portion with a second portion for apredetermined time period to produce a coffee enhancer; milling thecoffee enhancer to about 10-30 microns under cryogenic conditions in theabsence of oxygen; tempering the milled coffee enhancer in the absenceof oxygen; and prior to crystallization occurring, cooling the temperedcoffee enhancer in a cooling tunnel in the absence of oxygen.

Clause 66. The method of clause 65 or any other clause herein, whereinthe predetermined time period is about 1-30 minutes.

Clause 67. The method of clause 66 or any other clause herein, whereinthe mixer is a ribbon mixer operating under inert gas conditions in theabsence of oxygen.

Clause 68. The method of clause 66 or any other clause herein, whereinthe mixer is a sigma mixer operating under inert gas conditions in theabsence of oxygen.

Clause 69. The method of clause 66 or any other clause herein, whereinthe first portion comprises about 5-40% by weight of the coffeeenhancer.

Clause 70. The method of clause 66 or any other clause herein, whereinthe first portion comprises about 40-95% by weight of the coffeeenhancer.

Clause 71. The method of clause 66 or any other clause herein, whereinthe milling is performed in a horizontal or vertical ball mill.

Clause 72. The method of clause 71 or any other clause herein, furthercomprising conching the milled coffee enhancer under inert gasconditions in the absence of oxygen.

Clause 73. The method of clause 72 or any other clause herein, furthercomprising blending the conched coffee enhancer with a quantity ofconched, refined ingredients.

Clause 74. The method of clause 73 or any other clause herein, whereinthe second portion comprises butter oil.

Clause 75. The method of clause 74 or any other clause herein, whereinthe butter oil is cocoa butter oil.

Clause 76. The method of clause 74 or any other clause herein, whereinthe butter oil is cocoa butter substitute (CBS) oil.

Clause 77. A method, comprising: performing a wet cleaning on aplurality of biomaterials; performing a dry cleaning on the plurality ofbiomaterials; roasting the plurality of biomaterials under inert gasconditions and in an absence of oxygen; cooling the plurality ofbiomaterials under the inert gas conditions and in the absence ofoxygen; performing a cryogenic pre-milling on the plurality ofbiomaterials under the inert gas conditions and in the absence ofoxygen; performing a supercritical fluid extraction on the plurality ofbiomaterials under the inert gas conditions and in the absence of oxygento extract oil from the plurality of biomaterials; and generating aliquor based on the plurality of biomaterials.

Clause 78. The method of clause 77 or any other clause herein, furthercomprising, subsequent to performing the supercritical fluid extraction,milling the plurality of biomaterials under the inert gas conditions andin the absence of oxygen.

Clause 79. The method of clause 78 or any other clause herein, furthercomprising counching the plurality of biomaterials under the inert gasconditions and in the absence of oxygen.

Clause 80. The method of clause 77 or any other clause herein, furthercomprising: agglomerating the plurality of biomaterials under the inertgas conditions and in the absence of oxygen; and coating the pluralityof biomaterials under the inert gas conditions and in the absence ofoxygen.

Clause 81. The method of clause 77 or any other clause herein, furthercomprising packaging the plurality of biomaterials under the inert gasconditions and in the absence of oxygen.

Clause 82. The method of clause 77 or any other clause herein, furthercomprising: drying the plurality of biomaterials under the inert gasconditions and in the absence of oxygen; and discharging condensed waterfrom inert gas accumulated during the drying.

Clause 83. A method, comprising: roasting a plurality of biomaterialsunder inert gas conditions and in an absence of oxygen; crushing theplurality of biomaterials to extract oil under the inert gas conditionsand in the absence of oxygen; mixing the plurality of biomaterials in amixer under the inert gas conditions and in the absence of oxygen;drying the plurality of biomaterials in a dryer under the inert gasconditions and in the absence of oxygen; cooling the plurality ofbiomaterials under the inert gas conditions and in the absence ofoxygen; extruding the plurality of biomaterials under the inert gasconditions and in the absence of oxygen; and mixing the plurality ofbiomaterials with a fat under the inert gas conditions and in theabsence of oxygen.

Clause 84. The method of clause 83 or any other clause herein, furthercomprising receiving the plurality of biomaterials in a close loopmixer.

Clause 85. The method of clause 84 or any other clause herein, furthercomprising generating an inert gas atmosphere in the close loop mixer.

Clause 86. The method of clause 83 or any other clause herein, furthercomprising transferring the plurality of biomaterials from the mixerinto the dryer under the inert gas conditions and in the absence ofoxygen;

Clause 87. The method of clause 83 or any other clause herein, whereinthe cooled dried mixture comprises a moisture of less than 1.5%.

Clause 88. The method of clause 83 or any other clause herein, whereinthe fat comprises a deodorized cocoa butter.

Clause 89. The method of clause 83 or any other clause herein, furthercomprising: performing a wet cleaning on the plurality of biomaterials;and performing a dry cleaning on the plurality of biomaterials.

Clause 90. The method of clause 89 or any other clause herein, furthercomprising performing a fluid bed agglomeration of the plurality ofbiomaterials under the inert gas conditions and in the absence ofoxygen; and generating at least one of an instant cocoa or a chocolatepowder based at least in part on the plurality of biomaterials.

Clause 91. The method of clause 83 or any other clause herein, whereinthe plurality of biomaterials comprises a plurality of tea leaves, themethod further comprising generating at least one of a tea liquor basedat least in part on the plurality of biomaterials.

Clause 92. The method of clause 83 or any other clause herein, whereinthe plurality of biomaterials comprises a plurality of coffee beans, themethod further comprising generating at least one of a coffee liquorbased at least in part on the plurality of biomaterials.

Clause 93. A system comprising: an inert gas system; a blender coupledto the inert gas system configured to mix the plurality of biomaterialsunder inert gas conditions created by the inert gas system; a roastercoupled to the inert gas system, the roaster configured to roast aplurality of biomaterials under the inert gas conditions created by theinert gas system; and a fluid bed dryer coupled to the inert gas system,the fluid bed dryer configured to dry the plurality of biomaterialsunder the inert gas conditions created by the inert gas system.

Clause 94. The system of clause 93 or any other clause herein, whereinthe inert gas system comprises: an pipeline network configured totransport inert gas throughout the inert gas system; a line filterconfigured to remove particles from the inert gas; a separation cycloneconfigured to recover any solid particulates from the plurality ofbiomaterials; a heat exchanger configured to reduce the temperature ofthe inert gas; and a condenser configured to condense volatiles from theinert gas.

Clause 95. The system of clause 93 or any other clause herein, furthercomprising an extruder coupled to the inert gas system, wherein theextruder is configured to extrude the plurality of biomaterials underthe inert gas conditions created by the inert gas system.

Clause 96. The system of clause 93 or any other clause herein, furthercomprising a mixer coupled to the inert gas system, the mixer configuredto mix the plurality of biomaterials under the inert gas conditionscreated by the inert gas system.

What is claimed is:
 1. An edible coffee product comprising: coffeeliquor manufactured under inert conditions and in the absence of oxygencomprising: coffee particles milled to a particle size between about 0.1to 40 microns and a moisture content of less than about 1.25% undercryogenic and inert gas conditions in the absence of oxygen from coffeebeans roasted under inert gas conditions and in the absence of oxygen;and a substance encapsulating the coffee particles and substantiallypreventing oxidation of the coffee particles, the substance comprising:up to about 5% by weight of the coffee liquor; and one or more additivesderived from the coffee beans and comprising about 1-15% by weight ofthe coffee liquor selected from the group comprising fats, oils, andaromas, wherein the edible coffee liquor mass demonstrates a shelf lifeof at least one year under ambient temperature and pressure conditions.2. The edible coffee product of claim 1, wherein the moisture content isabout 1.14%.
 3. The edible coffee product of claim 1, wherein at least aportion of the coffee liquor is subjected to a Maillard reaction orStreker degradation.
 4. The edible coffee product of claim 1, wherein atleast a portion of the coffee particles are agglomerated.
 5. The ediblecoffee product of claim 4, wherein the agglomerated coffee particles areagglomerated with an aqueous solution.
 6. The edible coffee product ofclaim 4, wherein the agglomerated coffee particles are encapsulated. 7.The edible coffee product of claim 1, wherein at least a portion of thecoffee liquor is crystalized.
 8. The edible coffee product of claim 1,wherein the edible coffee product is a molded product.
 9. The ediblecoffee product of claim 1, wherein the edible coffee product is a coffeespread.
 10. The edible coffee product of claim 1, wherein the ediblecoffee product is a confectionary sweet.
 11. The edible coffee productof claim 1 further comprising sugar, or sugar alternatives or replacers.12. An edible coffee product comprising: coffee liquor manufacturedunder inert conditions and in the absence of oxygen comprising: coffeeparticles milled to a particle size between about 0.1 to 40 microns anda moisture content of less than about 5% under cryogenic and inert gasconditions in the absence of oxygen from coffee beans roasted underinert gas conditions and in the absence of oxygen; and a substanceencapsulating the coffee particles and substantially preventingoxidation of the coffee particles, the substance comprising: up to about5% by weight of the coffee liquor; and one or more additives comprisingabout 1-15% by weight of the coffee liquor selected from the groupcomprising fats, oils, and aromas, wherein the edible coffee liquor massdemonstrates a shelf life of at least one year under ambient temperatureand pressure conditions.
 13. The edible coffee product claim 12, whereinthe one or more additives are derived from the coffee beans.
 14. Theedible coffee product of claim 12, wherein the moisture content is lessthan about 1.25%.
 15. The edible coffee product of claim 14, wherein themoisture content is about 1.14%.
 16. The edible coffee product of claim12, wherein at least a portion of the coffee liquor is subjected to aMaillard reaction or Streker degradation.
 17. The edible coffee productof claim 12, wherein at least a portion of the coffee particles areagglomerated.
 18. The edible coffee product of claim 17, wherein theagglomerated coffee particles are agglomerated with an aqueous solution.19. The edible coffee product of claim 12, wherein the edible coffeeproduct comprises a molded product, coffee spread, or confectionarysweet.
 20. The edible coffee product of claim 12, wherein at least aportion of the coffee liquor is crystalized.